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Honda Power Equipment TPG-4300H-DX Portable Generator User Manual

1. Ref Part Ref Part No Number Description Qty No Number Description Qty 1 G01000062 Front Cover Generator 1 NOTE 1 Old rear cover G080001180 is no longer available When ordering replacement rear cover 7 order new rear 2 G020001231 Rotor C let 1 4 i Complete cover G080001252 and new muffler support bracket 18 3 0006205220 Bearing Ball 1 E070000230 4 0014810240 Bolt Through Tie Bolt 1 M10 X 260 P1 25 Ref Part 5 G 120001311 Cover Stator 1 No Number Description Qty 6 G040005820 Stator 1 H 1 GX240K1VED2 Engine Honda 7 G080001252 Rear Cover Generator 1 H2 hemtcenug Clamp Fuel Tube Not 1 Note 1 Shown 8 0013508140 Bolt Cover M8 X 140 4 H 3 Bolt Exhaust Flange 2 9 0030308000 Washer Spring M8 4 H 4 Gasket Exhaust Flange 1 10 G110000020 Cover Brush 1 H5 Sb oe eet Tank Fuel 1 11 0013705012 Bolt and Washer Assembly 2 H 6 Cushion 2 Ore eee Cap Filler 1 12 G070000130 Tube Flexible 1 T MEM Screen Fuel 1 13 0013708020 Bolt and Washer Assembly 4 Vl este aoe Bolt 2 Front Cover M8 X 20 14 0011204006 Screw and Washer Ground 1 Washer Fl t 2 Cable M4 X 6 H 11 Bushing Steel 2 14 1 C190000670 Wire Ground Not Shown 1 H 2 Bushing Rubber 2 15 H 13 Valve Fuel Shutoff 1 16 H 14 Seal Sediment Cup
2. TH 1 H 3 10 81 8 5 Fig 1 900 Ref Q TY Description AXLE ASSY RIGHT AXLE ASSY LEFT HANDLE RIGHT WITH GRIP HANDLE LEFT WITH GRIP TIRE U BOLT FOR AXLE ASSY SHORT U BOLT FOR HANDLE LONG HANDLE BRACKET PLAIN WASHER FOR TIRE o o o x o u 5 w N COTTER PIN FOR TIRE 11 SPRING WASHER 12 EMEN Oo o NUT 8 1 13 BOLT 8 20 14 NUT M8 3 Completed Chart HANDLE RIGHT WITH GRIP FOR HANDLE LONG U BOLT FOR AXLE ASSY TIRE HANDLE LEFT WITH GRIP AXLE ASSY RIGHT LEFT Appendix C Page C 2 Tsurumi s Operation Service and Repair Manual Step 1 Install Axle Assembly and Wheels 1 Follow this step carefully in order to do the installation 5 Important Ensure the bolts washers are balanced as task safely With the unit elevated place the block far apart to form a square which will hold the load of the unit between the ground and the lower chassis side where it meets the handle This will ensure that the necessary installation space is available 7 The axle assembly is adjustable with a sliding system The ad
3. Model Rotor Stator Condenser Field Insulation AC Winding AC Winding Condenser Insulation Capacitance Coil 1 2 Red White Red White Winding 2 3 Yellow Yellow TPG 2900H DX 1 70 gt 1MQ 0 58 0 58 1 56 gt 1MQ 24 uF TPG 4300H DX 1 75 gt 1MQ 0 29 0 29 0 74 gt 1MQ 50 uF TPG 6000H DX 1 58 gt 1MQ 0 22 0 22 0 57 gt 1MQ 56 uF TPG 7000H DXE 1 76 1MQ 0 18 0 18 0 46 1MQ 64 UF 1 Measure insulation across one of the solder terminals and the core of the rotor 2 Measure between stator leads as follows BLUE lead and core WHITE lead and core YELLOW lead and core and BROWN lead and core WARNING Do not use any part with insulation resistance of less than 1 MQ Low insulation resistance is an indication that the part is faulty insulation and may cause electrical leakage and potentially fatal electrical shock Replace all faulty parts Troubleshooting Page 28 Tsurumi s Operation Service and Repair Manual D TROUBLESHOOTING CHARTS This section provides the instructions for generator checkout and fault isolation The troubleshooting procedures are presented in Table 7 The table lists typical faults presents probable cause and pro vides the remedy for the majority of generator operational faults Table 7 Fault Isolation Procedures FAULT PROBABLE CAUSE REMEDY No AC output Condenser failed 1 Check condenser NOTE If you do not have measuring equipment
4. i Main coil l Condenser coil l 7 l i yal Condenser Figure 3 Generation of No Load Voltage Page 9 Description and Operation Tsurumi s Operation Service and Repair Manual 3 Full Power Switch Dual Voltage Type refer to Figure 4 a The full power switch provides both 120V and 240V dual voltages at full rated power The full rated power will be available from one 120V receptacle and one 240V recep tacle b Two main coils are wound over core of the stator Each main coil outputs half the rated power at the lower voltage 110V or 120V These main coils are wound so they are in the same phase The full power switch reconnects these main coils in parallel or in series c Refer to the circuit diagram in Figure 4 When the full power switch is set for single lower voltage indication 110V or 120V the switch position will be as indicated by the lower coils line in the diagram Rec 1 T 20V oz J or 110V 240V or 220V 120V or 110V NL fo aa Pe EERE Rec 3 d Rec 2 3 2 mE 120V or 110V Figure 4 Full Power Switch Circuit Diagram d Refer to Figure 5 for a simplified diagram of the circuit The two main coils are shown in parallel In this case the higher voltage 220V or 240V at Receptacle Rec 3 is not available Rec 2 for the lower voltage is available up to the rated powe
5. 35 SW 3211 Switch Engine 1 TO Sere eevee noe trees ete Ese 36 0013303008 Screw and Washer 2 71 Assembly M3X 8 72 0321302509 Grommet 1 U Vanes eee AE 72 1 0321090509 Grommet 1 38 39 40 bz 41 b 42 GF53BKA Receptacle 120V 1 GFCI 43 0022004000 Nut Flanged M4 2 44 45 0013304010 Screw and Washer 2 Assembly M4 X 10 46 0140111060 Pilot Light 1 4f 48 49 b 50 51 IEGBX618 Breaker 1 52 0015130510 Screw and Washer 2 Assembly 6 32 X 10 53 N A Washer Flat see 52 2 54 55 56 57 0021805000 Wing Nut M5 1 58 0030405000 Washer Spring M5 Ni 2 59 0021905000 Nut Hex M5 Ni 1 60 0030105000 Washer Flat M5 Ni 1 61 0030705000 Washer Lock M5 Ni 1 62 0010205015 Screw Grounding 1 M5 X 15Ni 63 C 220000440 Condenser 1 Page 67 Replacement Parts Tsurumi s Operation Service and Repair Manual 29 See separate exploded view for parts breakdown Exploded View Generator Model TPG 4300H DX Replacement Parts Page 68 Tsurumi s Operation Service and Repair Manual Parts List Generator Model TPG 4300H DX
6. 72 0321302509 Grommet 1 38 SW 3211 Switch Idle 1 72 1 0321090509 Grommet 1 39 0013303008 Screw and Lock Washer 2 72 2 0321201509 Grommet 1 Assembly M3 X 8 40 SW 3832 Switch Full Power 1 41 0013303008 Screw and Lock Washer 2 Assembly M3 X 8 42 GF53BKA Receptacle 120V GFCI 2 43 0022004000 Nut M4 4 44 i 45 0013304010 Screw and Washer 4 Assembly M4 X 10 46 01401110G0 Pilot Light 1 47 0065605130 Receptacle 120V Twist 1 lock 48 0015130510 Screw and Washer 2 Assembly 6 32 X 10 49 0065706320 Receptacle 120V 240V 1 Twist lock 50 0015130630 Screw and Washer 4 Assembly 6 32 X 10 51 IEGBX630 Breaker 1 52 0015130510 Screw and Washer 2 Assembly 6 32 X 10 53 N A Washer Flat see 52 2 54 IEGBX6620 Breaker 1 55 0015130510 Screw and Washer 2 Assembly 6 32 X 10 56 N A Washer Flat see 55 4 57 0021805000 Wing Nut M5 1 58 0030405000 Washer Spring M5 Ni 2 59 0021905000 Nut Hex M5 Ni 1 60 0030105000 Washer Flat M5 Ni 1 61 0030705000 Washer Lock M5 Ni 1 62 0010205015 Screw Grounding 1 M5 X 15Ni 63 C220000131 Condenser Set 2 per 1 set 64 C222000010 Condenser Holder 4 Page 75 Replacement Parts Tsurumi s Operation Service and Repair Manual 29 See separate exploded view for parts breakdown H 35 e Muffler Bracket Installation See separate view for battery enclosure
7. Cap Filler 1 Note 1 H 8 Screen Fuel 1 8 0013508160 Bolt Cover M8 X 160 4 H 9 Bolt 2 9 0030308000 Washer Spring M8 4 Washer Flat 2 10 G110000020 Cover Brush 1 UEM LS Bushing Steel 2 11 0013705012 ANEX a Assembly 2 H 42 Bushing Rubber 2 12 G070000130 Tube Flexible 1 TIS liegt Valve FVO Snag 1 13 0013708020 Bolt and Washer Assembly 4 Sealy sediment Cue 1 Front Cover M8 X 20 H 15 emen Cup Sediment 1 14 0011204006 Screw and Washer Ground 1 H16 Shield Inner 1 Cable M4 X 6 H 17 Seal 2 14 1 C190000670 Wire Ground Not Shown 1 418 z 2922 Nut 2 ToS eset Nu H 19 Support Muffler 1 19s ee eee ree re ee eos H 20 Muffler 1 df 4 seswemsesek Weise x H 21 Gasket Exhaust 1 18 E070000230 Bracket Muffler Support 1 Hz22 cae ds ER Shield Outer Muffler 1 E m PPM ONT HOS Bolt Flanged Muffler Shield 8 Brack et H 24 Spark Arrestor 1 M8 X 20 H 25 Screw Spark Arrestor 1 20 H 26 Screw Upper Muffler 1 21 0013006010 Bolt Flanged M6 x10 4 Support Support Bar H 34 Screw Brace to Shields 1 22 F020000610 Bar Support 2 H 35 Bolt 1 23 0013006012 Bolt Flanged M6 x12 2 H 36 Washer 1 24 E070000052 Brace Inner Shield 1 H 37 Spacer 1 25 0011305008 Screw
8. 3 OPERATING INSTRUCTIONS Tsurumi s Operation Service and Repair Manual A OPERATING CONTROLS 1 2 3 4 9 The main operating controls for the generator are with a few exceptions mounted on the front panel of the generator The controls consist of an ENGINE switch an IDLE switch a FULL POWER switch a PILOT light circuit BREAKER s a ground or earth post and electrical receptacles The specific controls used in each model are shown in Figures 7 through 10 The Model TPG 7000H DXE generator is equipped with a electric starter motor The ENGINE switch in this model is a key operated STOP RUN START switch The spring loaded switch is turned to the right to start the engine and to the left to shut off the engine The IDLE switch allows the generator speed to drop to idle speed if there is no electrical load demand on the generator When an electrical load is sensed the idle control increas es the speed of the generator up to operating speed level When there is no load the engine speed returns to idle The FULL POWER switch allows the generator to provide full rated power for the loading appliances and or tools When the FULL POWER switch is set to on power will be provid ed to only one 120 Vac receptacle and one 240 Vac receptacle The PILOT light provides an indication to the operator that the generator is generating elec tricity Circuit breakers are provided to protect the generator in t
9. DO NOT OPERATE THE GENERATOR BEFORE YOU HAVE READ AND UNDERSTAND THE INSTRUCTIONS AND THE ENGINE MANUFACTURER S MANUAL FAILURE TO DO SO COULD RESULT IN PERSONAL INJURY OR EQUIPMENT DAMAGE Introduction Page 2 Tsurumi s Operation Service and Repair Manual Placards shown below are provided on the portable generator to warn operating and maintenance per sonnel of potential hazards to provide maintenance information and to provide generator rating and capabilities The large label below is located on the front panel of the portable generator The label pres ents operational Warnings and Cautions for generator users TSURUMI GENERATOR MODEL OUTPUT MAX 2900W SER NO 1 DATA PLATE RATED 2400W VOLTAGE 120V 4f TSURUMI MANUFACTURING CO LTD OSAKA JAPAN FREQUENCY 60Hz FOR SPILLED FUEL OR FUEL LEAKS STOP ENGINE BEFORE REFUELING MCONTROLER QU IL N Y A NI FUITE NI ESSENCE REPANSUE SUR L APPAREIL ARR TER LE MOTEUR AVANT DE REFAIRE LE PLEIN MINSPECCIONAR PARA COMBUSTIBLE DERRAMADO ESCAPE PARAR MOTOR ANTES DE ECHAR FUEL WARNING PLACARD AIR CLEANER MAINTENANCE E CLEAN ELEMENT EVERY 50 HOURS EVERY 10 HOURS UNDER DUSTY CONDITIONS AIR CLEANER MAINTENANCE WASH IN HIGH FLASH POINT SOLVENT SQUEEZE DRY THEN DIP IN CLEAN ENGINE OIL AND SQUEEZE OUT EXCESS OIL HOT MUFFLER amp EXHAUST EXHAUST PLACARD ECHAPPEMENT CHAUD W
10. See No AC output above DC breaker tripped 1 Check the DC breaker 2 If the breaker was tripped while in use such as charging a battery check for a short circuit or reverse polarity connection After verifying that there are no shorted circuits or reversed polarity reset the breaker NOTE If the DC output was used to charge a large capacity battery or an excessively discharged battery there is a possibility that excessive current caused the DC breaker to trip Page 31 Troubleshooting Tsurumi s Operation Service and Repair Manual FAULT PROBABLE CAUSE REMEDY No DC output continued DC fuse blown Check DC fuse Check the fuse in the fuse holder in the control box If the fuse is blown determine the source of the fault Correct the fault in the DC circuit and replace the fuse 10 NOTE If the DC output was used to charge a large capacity battery or an excessively discharged battery there is a possibility that excessive current caused the DC breaker to trip Defective wiring 1 2 Check wiring Check wiring to make sure the wires are properly connected refer to the schematic diagrams in the Wiring Diagrams section for wiring information Correct wiring as required Defective diode rectifier Check the diode rectifier Remove the control panel Remove the control box and check the diode rectifier Using a multimeter check contin
11. 9 SC WHITE wa lt G WHITE IN LICO nez YELLOW us NI lt e O YELLOW C ai lt Wiring Diagram Model TPG 6000H DX Page 37 Troubleshooting Tsurumi s Operation Service and Repair Manual ENGINE CONTROL BOX GREEN W FIC SOL GREEN oH BLUE em lt Tuy EENMMI O HITE BLAI z WHITE K SW GREEN OS UN CE nox 2 h ds o g CB DI BAT 5 amp cup MSW NT S BLACK e co ER y Lx 6 lt LC zo SW gt IDLE WHITE 1 3 CONTROL 2 2 UNIT gt WHITE gt SOL ENGINE W NFB 1 BLACK Ps e lt SW B H 0 D SMCI 7 A BLUE ic o ew lt o_O YN X FC 5 96 H RED p 5 e lt eO ote e 3 9 O a JH 8 O e MC 11 9 J WHITE 55 SC e WHITE lt e I pn d NI Yello
12. 22 TsuRUMI PUMP OPERATION SERVICE AND REPAIR MANUAL FOR TSURUMI TPG SERIES PORTABLE GENERATORS MODELS TPG 2900H DX TPG 4300H DX TPG 6000H DX TPG 7000H DXE LIMITED WARRANTY TSURUMI MANUFACTURING CO LTD TSURUMI warrants to the original end purchaser during the warranty period every new TSURUMI generator or product to be free from defects in material and workmanship under normal use and service when properly installed used and maintained in accor dance with Tsurumi s Operation Service and Repair Manual for a period of two years from the date the unit was first installed or twenty six months from the date of shipment by TSURUMI to wholesaler whichever comes first TSURUMI S sole obligation under this warranty is to repair or replace at TSURUMI S option with new or remanufactured parts any part s that fail or that are found to be defective during the warranty peri od No allowance will be made for shipping charges damages labor or other charges due to failure repair or replacement This warranty does not apply to any TSURUMI product that has been disassembled without prior approval of TSURUMI nor does it apply to any product that has been subjected to misuse neglect alteration misapplication accident or act of God TSURUMI assumes no responsibility for compliance with any regulations codes standards or ordi nances applicable to the installation location operation or maintenance of
13. 23 OS UN__ E BLACK e 5 LC Bu IDLE WHITE 93 CONTROL gt gt UNIT 2T WHITE 2 I D SOL ENGINE NFB 1 BLACK M 2 SW 1 a doe D Ec 2 o3 G Te 4 oy 7 E s e G sot FC Os H RED pA eo oH e J a E MC2 L1 aH 05 WHITE A SC e l G WHITE CH e e YELLOW f m C ET ceu 8 Wiring Diagram Model TPG 4300H DX Troubleshooting Page 36 Tsurumi s Operation Service and Repair Manual ENGINE CONTROL BOX F C GREEN W SOL lt GREEN S SW 5 T O 293 225 lt IG BLACK e Ife Eo WHITE P7 CONTROL UNIT b WHITE VD SOL ENGINE NFB 1 BLACK p Tn Sw Vo p ENCI B E EE E BLUE 4 e lt Ld S e i FO 05 H RED E lt o 7 6 oO Fo IH EE ce 11
14. Engine Models Honda GX160K1VED2 GX240K1VED2 GX340K1ED6 GX390K1EDD2 Max HP rpm HP 5 5 3600 rpm 8 0 3600 rpm 11 0 3600 rpm 13 0 3600 rpm Displacement CC In 163 10 242 15 337 21 389 24 Fuel Tank Capacity Gals 2 9 4 5 4 5 4 5 2 Running Time at Rated Load Hours 14 6 22 0 8 5 14 2 5 7 8 5 5 3 8 1 1 2 Load Noise Level Rated Load 64 68 72 dB 78 dB Starting System Recoil Recoil Recoil Electric Recoil E Dimensions L x W x H Inches 23 1 4 x 18 x 20 1 4 25 34 x 20 h x 22 b 26 x 21 h x 22 1 26 x 21 h x 22 1 9 Shipping Weight Lbs 115 170 188 205 Page 5 Introduction Tsurumi s Operation Service and Repair Manual 2 DESCRIPTION AND OPERATION A PHYSICAL DESCRIPTION 1 Description of the Portable Generator a The key features of the portable generator are shown in Figure 1 A cutaway view of the generator is provided in Figure 2 Filler Cap Fuel Tank Fuel Gauge Controls Air Filter Front Panel Vibration Mounts Tubular Frame Control Box Spark Arrestor Figure 1 Key Features of Generator Model TPG 7000H DXE Shown Description and Operation Page 6 Tsurumi s Operation Service and Repair Manual 2 b c The generator consists of a tubular frame onto which is installed the generator engine front panel control box and fuel tank The generator and engine are installed on cros
15. Removal Installation of Front Panel and Control Box b Remove fuse H 32 from its fuse holder c Install replacement fuse H 32 in its fuse holder d Install front panel 29 and control box 32 refer to Removal Installation of Front Panel and Control Box Removal Installation Page 58 Tsurumi s Operation Service and Repair Manual 5 6 7 8 9 Engine Start Key Switch TPG 7000H DXE d e Refer to Figure 35 Remove ring nut H 28 and fiber washer H 29 Pull switch H 2T from backside of front panel 29 Separate switch from its connector Align notch in panel with the key on the switch Install replacement switch 35 in back side of front panel 29 Install fiber washer H 29 and ring nut H 28 Tighten ring nut H 28 Connect switch with mating connector Engine Switch Models TPG 2900H DX TPG 4300H DX and TPG 6000H DX Refer to Figure 36 Remove front panel 29 and control box 32 refer to Removal Installation of Front Panel and Control Box Disconnect wiring Connect wiring and install replacement switch 35 in back of front panel 29 Secure with screw and washer assemblies 36 Install front panel 29 and control box 32 refer to Removal Installation of Front Panel and Control Box Pilot Lamp ALL MODELS b c d e Refer to Figure 36 Remove front panel 29 and control box 32 refer to Removal Installation of Front P
16. and TPG 7000H DXE a Refer to Figure 36 Remove front panel 29 and control box 32 refer to Removal Installation of Front Panel and Control Box b Remove two screw and lock washer assemblies 39 from switch 38 c Disconnect wiring d Connect wiring and install replacement switch 38 in back of front panel 29 Secure with two screw and lock washer assemblies 39 e Install front panel 29 and control box 32 refer to Removal Installation of Front Panel and Control Box Removal Installation Page 60 Tsurumi s Operation Service and Repair Manual 11 12 13 Full power Switch Models TPG 4300H DX TPG 6000H DX and TPG 7000H DXE b c d e Refer to Figure 36 Remove front panel 29 and control box 32 refer to Removal Installation of Front Panel and Control Box Remove two screw and lock washer assemblies 41 from switch 40 Disconnect wiring Connect wiring and install replacement switch 40 in back of front panel 29 and secure with two screw and lock washer assemblies 41 Install front panel 29 and control box 32 refer to Removal Installation of Front Panel and Control Box Twist Lock Receptacles f 9 h Refer to Figure 36 Install front panel 29 and control box 32 refer to Removal Installation of Front Panel and Control Box For receptacle 47 remove two screw and lock washer assemblies 48 Disconnect wiring Connect
17. in holes in base plate 2 Put threaded ends of tie down rods 5 up through holes in hold down plate 4 Install raised edge clips 6 toward terminals Install wing nuts 7 on tie down rods Tighten wing nuts 7 Connect battery cables to terminals Start the generator to verify that the battery is properly connected Page A 3 Appendix A Tsurumi s Operation Service and Repair Manual APPENDIX B PGWK 100 WHEEL KIT INSTALLATION INSTRUCTIONS Appendix B Page B 1 Tsurumi s Operation Service and Repair Manual WHEEL KIT INSTALLATION INSTRUCTIONS FOR TSURUMI GENERATORS AND PUMPS 12 DRILL 3 8 INCH HOLES HEREIN PUMP FRAME dee pee PUMP AXLE 3 Ls ARRANGEMENT DRILL 3 8 INCH B nod GENERATOR FRAME View A Ref Part No Description Qty Ref Part No Description Qty 1 PGWK 1 Handle Left 1 9 PGWK 9 Screw 4 2 PGWK 2 Handle Right 1 10 PGWK 10 Nut 4 3 PGWK 3 Clamp Handle 4 11 PGWK 11 U Bolt 2 4 PGWK 4 Plate Handle Clamp 4 12 PGWK 12 Plate U Bolt 2 5 PGWK 5 Screw 8 13 PGWK 13 Nut 4 6 PGWK 6 Nut 8 14 PGWK 14 Wheel 2 7 PGWK 7 Axle 1 15 PGWK 15 Cap Axle 2 8 PGWK 8 Clamp Axle 2 16 PGWK 16 Grip Handle 2 KIT CONTENTS Check to make sure the following parts are included the kit Contact Tsurumi to obtain any missing parts DRAIN FLUIDS Drain o
18. 1 17 H 15 Cup Sediment 1 18 E070000230 Brace Muffler Support 1 16 Shield Inner 1 Note 1 Hag Seal 2 19 0013708020 Bolt and Washer Assembly 2 218 Nut 2 Bracket to Rear Cover M8 X 20 H 19 Support Muffler 1 oO H 20 Muffler 1 21 0013006010 Bolt Flanged M6 x10 4 IUE p esentese Gasket Exhaust 1 Support Bar 22 Shield Outer Muffler 1 22 F020000600 Bar Support 2 H 23 Bolt Flanged Muffler 8 23 0013006012 Bolt Flanged M6 x12 2 Shield 24 E070000440 Brace Inner Shield 1 Hi2 eee ee Spark Arrestor 1 25 0011305008 Screw and Washer 1 eee saspe Screw Spark Arrestor 1 Assembly M5 X 8 NI H 26 Screw Upper Muffler 1 25 1 F070000230 Cable Ground 1 Support 26 0022008000 Nut Flanged 12 Screw Brace to Shields 1 27 G060000492 Mount Vibration Isolator 6 Lc c ccu Bolt 1 Engine amp Generator H 36 Washer 1 27 1 G150000421 Spacer 2 H 37 Spacer 1 28 F011003202 Frame 1 NOTE Items prefixed with letter H are Honda Engine parts 29 C012011860 Front Panel Complete 1 Refer to Honda Parts Catalog for part numbers Page 69 Replacement Parts Tsurumi s Operation Service and Repair Manual Exploded View Front Panel Model TPG 4300H DX Replacement Parts Page 70 Tsurumi s Operation Service and
19. 1 Twist lock 50 0015130510 Screw and Washer 2 Assembly 6 32 X 10 51 IEGBX6614 Breaker 20A 1 52 0015130510 Screw and Washer 4 Assembly 6 32 X 10 53 N A Washer Flat see 52 4 54 55 56 57 0021805000 Wing Nut M5 1 58 0030405000 Washer Spring M5 Ni 2 59 0021905000 Nut Hex M5 Ni 1 60 0030105000 Washer Flat M5 Ni 1 61 0030705000 Washer Lock M5 Ni 1 62 0010205015 Screw Grounding 1 M5 X 15 63 C220000390 Condenser Set 2 per set 1 Page 71 Replacement Parts Tsurumi s Operation Service and Repair Manual 29 See separate exploded view for parts breakdown Exploded View Generator Model TPG 6000H DX Replacement Parts Page 72 Tsurumi s Operation Service and Repair Manual Parts List Generator Model TPG 6000H DX Ref Part Ref Part No Number Description Qty No Number Description Qty 1 G010000551 Front Cover Generator 1 H 1 GX340K1ED6 Engine Honda 2 G020001241 Rotor Complete 1 H 2 Clamp Fuel Tube Not 1 3 0006205ZZ0 Bearing Ball 1 Shown 4 0014810260 Bolt Through Tie Bolt 1 bios oannes Bolt Exhaust Flange 2 M10 X 260 P1 25 H 4 Gasket Exhaust Flange 1 5 G120001331 Cover Stator 1 H 5 Tank Fuel 1 6 G040005830 Stator 1 H 6 Cushion 2 7 G080001262 Rear Cover Generator 1 H 7
20. Connect a drain hose to the fuel tank shutoff valve and place the free end of the tube in an approved gasoline container The container should have a capacity of 4 5 gal lons minimum e Open the fuel shutoff valve H 13 and allow the fuel to drain from the tank f Tighten the cap on the fuel container Page 45 Removal Installation WARNING Tsurumi s Operation Service and Repair Manual Figure 25 Fuel Shutoff Valve Shown in CLOSED Position DO NOT DRAIN FUEL WHILE SMOKING OR WHILE IN CLOSE PROXIMITY TO OPEN FLAME ENGINE FUEL GASOLINE IS HIGHLY FLAMMABLE AND IF ACCIDENTALLY IGNITED CAN CAUSE SEVERE BURNS AND DEATH MAKE SURE THAT YOU DISCONNECT OR REMOVE THE BATTERY BEFORE DRAINING FUEL OR WHENEVER MAINTENANCE WILL INVOLVE HANDLING ENGINE FUEL ENGINE FUEL IS EXTREMELY FLAMMABLE AND CAN CAUSE SEVERE OR FATAL BURNS IF IGNITED MAKE SURE THAT YOU DISCONNECT OR REMOVE THE BATTERY WHEN YOU DO MAIN TENANCE EXPLOSIVE HYDROGEN GAS MAY BE PRESENT AROUND THE BATTERY SPARKS FROM STATIC ELECTRICITY OR FROM HAND TOOLS CONTACTING BATTERY TERMINALS CAN CAUSE THE HYROGEN GAS TO EXPLODE CAUSING INJURY AND BURNS TO NEARBY PERSONNEL NOTE Refer to exploded view in Replacement Parts section for parts information The item numbers in the following procedure are identical to those in the Replacement Parts exploded views 2 Removal of Fuel Tank a b
21. EU HONDA O 7 LEGEND 1 Engine Switch 6 22Amp Circuit Breaker 2 Idle Switch 7 Ground Post 3 Pilot Light 8 Receptacle 120Vac 240Vac 4 Full Power Switch 9 Receptacle 120Vac 5 30 Amp Circuit Breaker 10 Receptacle 120Vac GFI 2 Figure 10 Model TPG 7000H DX Operating Instructions Page 14 Tsurumi s Operation Service and Repair Manual Fuel Tank Reset Button Control Box Figure 11 DC Circuit Reset Pushbutton C CHECK THE ENGINE OIL LEVEL CAUTION Engine oil is a major factor affecting performance and service life Non detergent oils and 2 stroke oils are not recommended because they have inadequate lubricating characteristics Check the oil level with the engine on a level surface and the engine stopped 1 Use Honda 4 stroke oil or use an equivalent high detergent premium quality motor oil cer tified to meet or exceed U S automobile manufacturer s requirements for Service Classification SG SF Motor oils classified SG SF will show this designation on the con tainer 2 SAE 10W 30 is recommended for general all temperature use 3 Other viscosity grades shown in Figure 12 may be used when the average temperature in your area is within the indicated range 1 20 30 az Figure 12 Oil Viscosity Grade to Temperature Recommendations Page 15 Operating Instructions Tsurumi s Operation Service and Repair Manual When checking oil observ
22. OR CAUSE FIRES IN THE BUILDING S ELECTRICAL SYSTEM H ACAPPLICATION A Single Voltage Type 1 Check the pilot lamp for proper voltage NOTE The generator is thoroughly tested and adjusted in the factory If the generator does not produce the specific voltage consult your nearest Tsurumi Generator dealer 2 Set switches on the electrical appliances to OFF before connecting to the generator 3 Insert the plug of the electrical appliance into the appropriate receptacle Operating Instructions Page 18 Tsurumi s Operation Service and Repair Manual NOTE Check the amperage of the receptacles used referring to Table 2 and be sure not to take a current exceeding the specified amperage Be sure that the total wattage of all appliances does not exceed the rated output of the generator WARNING e TO CONNECT AND LOCK A PLUG IN A TWIST LOCK RECEPTACLE INSERT THE PLUG INTO RECEPTACLE AND TURN CLOCKWISE BESURE TO GROUND THE GENERATOR IF THE CONNECTED ELECTRICAL EQUIPMENT IS GROUNDED NOTE When the circuit breaker trips off during operation the generator is overloaded or the appliance is defective When the circuit breaker trips stop the generator immediately Check the appliance and or gener ator for an overload or defect and repair as necessary Table 2 Receptacle Types and Amperage Style Ampere Receptacle AC Plug Description Receptacle Duplex GFCI Up to NEMA
23. Probe of the Circuit Tester 1 2 3 4 5 Apply Red 1 E 250 kQ 250 kQ 250 Positive Probe of Circuit Tester 2 cos ig ui 3 250 ao 250 kO 75 KQ 4 250 kQ 250 75 kQ 5 8 5 KQ 7 8 KQ 7 8 KQ Table 9 Diode Rectifier Checking Apply Black Negative Probe of the Circuit Tester Using BRNO Teste Brown Brown Orange Brown White Brown No Continuity No Continuity Continuity Brown No Continuity No Continuity Continuity Apply Red Positive Probe of Orange Continuity Continuity Continuity Circuit Tester Brown White No Continuity No Continuity No Continuity Apply Red Positive Probe of the Circuit Tester Peete Mule Teste Brown Brown Orange Brown White Brown No Continuity No Continuity Continuity Apply Black Negative Probe Brown No Continuity No Continuity Continuity of Circuit Tester Orange Continuity Continuity Continuity Brown White No Continuity No Continuity No Continuity NOTE Simpson brand analog testers have the same characteristics as a digital tester NOTE Because of the difference of measuring methods between the analog circuit tester and the digital circuit tester polarity of the tester needles should be reversed NOTE Continuity means forward direction characteristics of the diode and is different from short circuit condition in which a pointer of the tes
24. Threaded Rod Figure 29 Bearing Puller in Use l REPLACEMENT OF ROTOR 1 The generator stator 6 Figure 28 must be removed before the rotor 2 can be removed Refer to Replacement of Stator for stator removal instructions Page 53 Removal Installation Tsurumi s Operation Service and Repair Manual NOTE The rotor 2 Figure 28 at this point is free to rotate and must be kept from rotating to enable removal of the through bolt 4 2 Restrain the rotor to keep it from rotating 3 Puta box end wrench on the hex of the through bolt 4 4 Using a plastic rubber or other soft faced hammer strike the side of the wrench using sharp blows to loosen the through bolt 4 5 When the through bolt 4 is loosened it can easily be removed Through Figure 30 Removal of Through Bolt NOTE Inthe steps that follow motor oil is used to generate hydraulic pressure Hydraulic pressure is used to separate the tight fitting engine and generator shafts 6 Refer to Figure 31 With the generator in the vertical position pour a small amount of motor oil in the bore in the center of the rotor shaft The oil level should be flush with the end of the rotor shaft Oil Container E Sx E Rotor Figure 31 Pouring Oil in Rotor Shaft Removal Installation Page 54 Tsurumi s Operation Service and Repair Manual 7 Refer to Figure 32
25. also increases at the rotor s magnetic pole and continues to increase as generator speed increases As AC current flows through the condenser coil the density of the magnetic flux in the rotor changes The change in magnetic flux density induces AC voltage in the field coil and the diode rectifier in the field coil circuit rectifies the AC voltage into DC voltage The resultant DC current flows b through the field coil and magnetizes the rotor core to generate output voltage in the main coil When the generator speed reaches 3000 to 3300 rpm 60 Hz generators the current in the condenser coil increases rapidly This acts to stabilize the output voltage of each coil When the generator speed reaches its rated speed the generator output will be at its rated value 2 Voltage Fluctuations Under Load refer to Figure 3 When output current c flows through the main coil to the appliance being used a magnetic flux is produced and serves to increase current a in the condenser coil As a result the current flowing in the field coil increases and the generator output voltage is prevented from decreasing Stator AES ees Main coil Permanent magnet l for initial excitation 1 F co d rn Cc ax ES 1 1 N Surge zy p qu em absorber 4 i E Receptacle li 1 ar aT Field coil Diode
26. and Washer Assembly 1 NOTE Items prefixed with letter H are Honda Engine parts M5 X 8 NI Refer to Honda Parts Catalog for part numbers 25 1 F070000230 Cable Ground 1 26 0022008000 Nut Flanged 12 27 G060000492 Mount Vibration Isolator 4 Engine 27 1 G150000421 Spacer 27 2 G060000482 Mount Vibration Isolator Generator Page 73 Replacement Parts Tsurumi s Operation Service and Repair Manual ES E d JR WEE DAS r Exploded View Front Panel Model TPG 6000H DX Page 74 Replacement Parts Tsurumi s Operation Service and Repair Manual Parts List Front Panel Model TPG 6000H DX Ref Part Ref Part No Number Description Qty No Number Description Qty 30 011017991 Front Panel less parts 1 65 0011204010 Screw and Washer 4 30 1 C011900180 Label 1 Assembly M4 X 10 31 0013006010 Bolt Flanged M6 X 10 4 66 0011204018 Screw and Washer 1 32 C020004716 Control Box Complete 1 Assembly M4 X 18 33 C021103684 Control Box Less Parts 1 67 ness Ssi omani tuis 5 34 0014305012 Screw and Washer 4 68 HaOHe Stack 1 Assembly M5 X 12 69 C150000250 Idle Control Unit 1 35 SW 3116 Switch Engine Stop 1 70 0011204006 Screw and Washer 2 36 0013303008 Screw and Lock Washer 2 Assembly M4 X 6 Assembly M3 X 8 71 37
27. and then check for 120 vac 5 from the black blue wires If the voltage is correct the failure is in the control panel If the voltage is too low from either coil the defect lies in the rotor stator or condensers B MEASURING INSULATION RESISTANCE refer to Figure 20 5 6 No AC output Measuring Insulation Resistance Use a megger tester to test each component for prop er insulation An insulation resistance of 1 MQ or greater is normal The insulation resistance from the factory is at least 10 MO Insulation Resistance Stator a Measure the insulation resistance between BLUE lead and the core 6 Measure the insulation resistance between WHITE lead and the core c Measure the insulation resistance between YELLOW lead and the core d Measure the insulation resistance between BROWN lead and the core Insulation Resistance Rotor a Measure the insulation across one of the sol dered terminals of the rotor and the core b Parts with insulation resistance of less than 1MQ have faulty insulation and may cause electric leakage and electric shock Replace Figure 20 Measuring Resistance the faulty part Page 27 Troubleshooting Tsurumi s Operation Service and Repair Manual C ELECTRICAL LIMITS REFERENCE CHART The Electrical Limits Reference Chart Table 6 provides a ready reference to electrical component limits Table 6 Electrical Limits Reference Chart
28. clamp 3 and plate 4 and install screws for attaching handle clamp 5 and nuts 6 Tighten screws 5 and nuts 6 Install han dle grips 16 on handles View B 2 S i ull Appendix B Tsurumi s Operation Service and Repair Manual APPENDIX C PGWK 200 WHEEL KIT INSTALLATION INSTRUCTIONS Page C 1 Appendix C Tsurumi s Operation Service and Repair Manual P Product Features DESIGNED FOR LIFELONG DURABILITY STATE OF THE ART ADJUSTABLE SLIDING AXLE SYSTEM FITS MOST GENERATOR SIZES AND PUMPS HIGHEST QUALITY METAL TUBING ALL BRACKETS ARE PRECISION FIT WIDE ANGLE HANDLE BARS FOR EASY PORTABILITY EASY COMFORTABLE GRIP DOUBLE BALL BEARINGS ON EACH AIRLESS TIRE IMPOSSIBLE TO PUNCTURE SMOOTH SLEEK DESIGN Before Installation Ensure there is no oil in the engine and the oil is properly drained from the engine Ensure there is no gasoline in the fuel tank and close the fuel petcock at the base of the fuel tank Drain fuel from carburetor bowl Ensure the wheel kit contains the appropriate pieces See Fig 1 m This installation is best performed by two people m Please support the underside of the dolly with a sturdy and stable block WHEEL KIT PGWK 200 FITS TSURUMI PUMPS amp GENERATORS TSURUM PUMP Installation Instructions Wheel Kit Parts Include nnnne NANNAN
29. covers 18 Tighten fasteners to the torque values shown in Table 10 H REPLACEMENT OF ROTOR BEARING NOTE Refer to exploded view in Replacement Parts section for parts information The item numbers in the following procedure are identical to those in the Replacement Parts exploded views 1 Remove the generator rear cover 7 Refer to Replacement of Stator for removal instruc tions NOTE Make sure the diameter of the bearing puller threaded rod is larger than the threaded bore in the center of the rotor shaft 2 Install a three jaw gear or bearing puller on the rotor shaft Make sure all three jaws are under the outer race of the bearing refer to Figure 29 3 Rotate the threaded rod of the bearing puller and remove the bearing 3 from the rotor shaft 2 Removal Installation Page 52 Tsurumi s Operation Service and Repair Manual 4 Pre heat an oven to 350 25 Fahrenheit Place the replacement bearing 3 in the oven for 30 minutes WARNING TO AVOID BEING BURNED BY THE HEATED BEARING WEAR THERMAL INSULATED GLOVES 5 Wear insulated gloves and remove bearing from the oven Immediately place the bearing on the rotor shaft Make sure the bearing is seated against the shoulder of the shaft 6 Let the bearing cool to room temperature 7 Check the bearing for free rotation 8 Install the rear cover 1 Refer to Replacement of Stator for rotor installation instructions Puller
30. ends of U bolts 11 and install nuts 13 Before tightening nuts make sure axle extends an equal amount from the sides of the pump frame Tighten nuts 13 INSTALL WHEELS 1 2 Position hub side of wheel toward frame and slide wheel 14 onto axle 7 Install cap 15 over end of axle 7 and drive onto axle using a hammer Repeat step 1 for the second wheel 14 INSTALL HANDLES 1 Position frame upright on wheels Place frame into channel at lower end of the left handle 1 Position the left handle 1 against the vertical tube of the frame Hold one clamp 3 on the outside of the frame and one plate 4 on the inside of the frame Align holes in clamp and plate and install screws 5 Install nuts but do not tighten If wheel kit is being installed on a pump repeat steps 1 and 2 for right handle 2 then proceed to step 9 If you are installing the kit on a portable generator complete steps 5 through 8 A 5 16 inch hole must be drilled through the generator s front panel to enable installation of one of the handle clamp screws Hold a handle clamp 3 against the generator s right handle and front panel Use a center punch and mark the location of the hole in clamp 3 on the front panel Use the center punch dimple as a guide and drill a 5 16 inch hole through the front panel see View B Position clamp 3 over the frame and over the hole in the front panel Align holes in Drill one 5 16 inch hole here
31. in START position until engine starts c d e Release key the key is spring loaded to the RUN position As the engine warms up gradually move the choke lever to the OPEN position Position the throttle lever at the desired engine speed ALL MODELS When starting the engine using recoil starter proceed as follows a Turn the engine switch to the ON position b Pull the starter grip lightly until resistance is felt then pull briskly NOTE When using the recoil starter do not allow the starter grip to snap back against the engine Return it gently to prevent damage to the starter c As the engine warms up gradually move the choke lever to the OPEN position d Position the throttle lever at the desired engine speed G USING THE GENERATOR WARNING TO PREVENT ELECTRICAL SHOCK FROM FAULTY APPLIANCES THE GENERATOR SHOULD BE GROUNDED CONNECT A LENGTH OF HEAVY WIRE BETWEEN THE GENERA TOR S GROUND TERMINAL AND EXTERNAL GROUND SOURCE CONNECTIONS FOR STANDBY POWER TO A BUILDING S ELECTRICAL SYSTEM MUST BE MADE BY A QUALIFIED ELECTRICIAN AND MUST COMPLY WITH ALL APPLICABLE LAWS AND ELECTRICAL CODES IMPROPER CONNECTIONS CAN ALLOW ELECTRICAL CUR RENT FROM THE GENERATOR TO BACK FEED INTO THE UTILITY LINES SUCH BACK FEED MAY ELECTROCUTE UTILITY COMPANY WORKERS OR OTHERS WHO CONTACT THE LINES DURING A POWER OUTAGE AND WHEN UTILITY POWER IS RESTORED THE GENERATOR MAY EXPLODE BURN
32. install a known good condenser Start the generator and check ac output If the generator ac output is normal the fault was in the original condenser 2 Short the condenser leads across each other to discharge the condenser NOTE To make sure you get a good reading discharge the condenser before checking capacitance 3 Check capacitance of condensers refer to Table 6 for capacitance values for each generator model Replace condensers that do not meet normal capacitance Stator fault 1 Check Stator 2 Remove bolts 31 from front panel 30 Pull the front panel 30 away from frame 28 to provide clearance for removal of control box 3 Remove four screws 34 from front panel 30 to separate the control box 32 from the front panel 4 Locate the stator leads Separate the leads at the in line connector 5 Use an adhesive label or tag to identify the leads use the label or tag to make sure you have the proper connection 6 Measure resistance between the in line connector on the stator leads refer to Table 6 for resistance values for each generator model 7 Replace stator if it does not meet resistance values in Table 6 Page 29 Troubleshooting Tsurumi s Operation Service and Repair Manual FAULT PROBABLE CAUSE REMEDY No AC output Check insulation resistance between the stator core and each stator leads Check using a megger tester Replace the stator
33. parts Exploded View Generator Model TPG 7000H DXE Replacement Parts Page 76 Tsurumi s Operation Service and Repair Manual Parts List Generator Model TPG 7000H DXE Ref Part Ref Part No Number Description Qty No Number Description Qty 1 G010000551 Front Cover Generator 1 28 F011003215 Frame 1 2 G020001591 Rotor Complete 1 29 C012011890 Front Panel Complete 1 3 0006205770 Bearing Ball 1 NOTE Old rear cover G080001 190 is no longer available When ordering replacement rear cover 7 order new rear 0014819279 Abr 1 cover G080001262 and new muffler support bracket 18 E070000230 5 G120001341 Cover Stator 1 Ref Part 6 G040006380 Stator 1 No Number Description Qty 7 G080001262 Rear Cover Generator 1 H 1 GX390K1EDD2 Engine Honda 3018 3 H 2 Clamp Fuel Tube Not 1 8 0013508170 Bolt Cover M8 X 160 4 Shown 9 0030308000 Washer Spring M8 4 H 3 Bolt Exhaust Flange 2 10 G110000020 Cover Brush 1 AAs 2 Gasket Exhaust Flange 1 11 0013705012 Bolt and Washer Assembly 2 E zzi Tank Fuel 1 MSX 12 H 6 Cushion 2 12 G070000130 Tube Flexible 1 ttre Cap Filler 4 13 0013708020 Bolt and Washer Assembly 4 H 8 S Fuel 4 Front Cover M8 X 20 E creen tue 14 0011204006 Screw Washer Ground 1 BS Sears es Bolt 2 Cable M4 X 6 H 10 Washer Flat 2 14 4 C1900
34. 00 4500 5300 Fluorescent Lamp Mercury Lamp 1200 1900 2800 3100 Electric Tool 1200 1900 2800 3100 Pump Compressor 500 700 1000 1500 Operating Instructions Page 22 Tsurumi s Operation Service and Repair Manual 4 MAINTENANCE To maintain the generator in peak operating condition observe and implement the maintenance and adjustment schedule in Table 5 Inspect and or service the generator as scheduled in Table 5 WARNING SHUT OFF THE ENGINE BEFORE PERFORMING ANY MAINTENANCE IF OPERATION OF THE ENGINE IS REQUIRED MAKE SURE THE AREA IS WELL VENTILATED THE ENGINE EXHAUST CONTAINS POISONOUS CARBON MONOXIDE GAS CAUTION Refer to the Honda engine owner s manual for other maintenance requirements An initial oil change should be performed after the first twenty 20 hours of use Thereafter change oil every 100 hours Before changing the oil check for a suitable way to dispose of the used oil Do not pour it down sewer drains onto garden soil or into open streams Refer to your local zoning and environmental regula tions for disposal and handling requirements Table 5 Maintenance Schedule Daily e Check oil level e Check all components according to the PRE OPERATIONAL CHECKS section 50 Hours e Wash cleaner element e Check spark plug and clean if necessary 100 Hours e Change engine oil 200 Hours e Adjust spark plug gap e Clean fuel strainer 500 Hours e Replac
35. 00670 Wire Ground Not Shown 1 H 11 Bushing Steel 2 15 Bolt Lower Muffler Support 1 H 12 Bushing Rubber 2 16 Washer 1 H 13 Valve Fuel Shutoff 1 17 Spacer Tubular 1 H 14 Seal Sediment Cup 1 18 E070000230 Bracket Muffler Support 1 H 15 Cup Sediment 1 Note 1 Hee eaves Shield Inner 1 19 0013708020 Bolt and Washer Assembly 1 H 17 Seal 2 M8 X 20 H 18 Nut 2 S Ee eras H 19 S 1 21 0013006012 Bolt Flanged M6 x10 4 pin Spe Ea upport Muffler Support Bar H 20 Muffler 1 22 F020000600 Bar Support 2 H 21 Gasket Exhaust 1 23 0013006010 Bolt Flanged M6 x12 2 H 22 Shield Outer Muffler 1 24 E070000052 Brace Inner Shield 1 H 23 Bolt Flanged Muffler Shield 8 25 0011305008 Screw and Washer Assembly 1 H 24 Spark Arrestor 1 M5 X 10 NI H 25 Screw Spark Arrestor 1 25 1 F070000230 Cable Ground 1 H6 esse Screw Upper Muffler 1 26 0022008000 Nut Flanged 12 Support 27 G060000492 Mount Vibration Isolator 4 H 34 Screw Brace to Shields 1 Engine H 35 Bolt 1 27 1 G150000421 Spacer 2 Hi36 xxm Washer 1 27 2 G060000482 Mount Vibration Isolator 2 H37 akaid Spacer 1 Generator NOTE Items prefixed with letter H are Honda Engine parts Refer to Honda Parts Catalog for part numbers Page 77 Replacement Parts Tsurumi s Operat
36. APOR OR SPILLED FUEL MAY IGNITE 1 The following procedures should be followed before storing your generator for periods of 6 months or longer WARNING Carefully drain fuel from the fuel tank gasoline left in the fuel tank will eventually dete riorate making engine start difficult Remove the carburetor float chamber and also drain the carburetor Change engine oil Check for loose bolts and screws tighten if necessary Clean generator thoroughly with oiled cloth Spray with preservative if available NEVER USE WATER TO CLEAN GENERATOR Pull starter handle until resistance is felt leaving handle in that position Store generator in a well ventilated low humidity area TO PREVENT ELECTRICAL SHOCK FROM FAULTY APPLIANCES THE GENERATOR SHOULD BE GROUNDED CONNECT A LENGTH OF HEAVY WIRE BETWEEN THE GENERA TOR S GROUND TERMINAL AND EXTERNAL GROUND SOURCE CONNECTIONS FOR STANDBY POWER TO A BUILDING S ELECTRICAL SYSTEM MUST BE MADE BY A QUALIFIED ELECTRICIAN AND MUST COMPLY WITH ALL APPLICABLE LAWS AND ELECTRICAL CODES IMPROPER CONNECTIONS CAN ALLOW ELECTRICAL CURRENT FROM THE GENERATOR TO BACKFEED INTO THE UTILITY LINES SUCH BACKFEED MAY ELECTROCUTE UTILITY COMPANY WORKERS OR OTHERS WHO CONTACT THE LINES DURING A POWER OUTAGE AND WHEN UTILITY POWER IS RESTORED THE GENERATOR MAY EXPLODE BURN OR CAUSE FIRES IN THE BUILDING S ELECTRICAL SYSTEM Storage Instructions Page 62 Tsurumi s Operation Service and R
37. ARNING DO NOT USE INDOORS EXHAUST NO LO USE EN LUGARES CERRADOS GAS CONTAINS POISONOUS PORQUE EL MONOXIDE DE CARBONO CARBON MONOXIDE ES VENENOSO WARNING USING THE GENERATOR IN RAIN SNOW OR NEAR WATER CAN LEAD TO DEATH FROM ELECTRIC SHOCK KEEP GENERATOR DRY WARNING ELECTROCUTION OR PROPERTY DAMAGE CAN OCCUR DO NOT CONNECT THIS GENERATOR TO ANY BUILDING S ELECTRICAL SYSTEM UNLESS AN ISOLATION SWITCH HAS BEEN INSTALLED BY A LICENSED ELECTRICIAN READ OWNER S MANUAL CAREFULLY PPP CAUTION NOT RESPONSIBLE WHEN EXCEEDING GENERATORS WATTAGE AMPERAGE CAPACITY CAN DAMAGE GENERATOR AND OR ELECTRICAL DEVICES CONNECTED TO IT START GENERATOR AND LET ENGINE STABILIZE BEFORE CONNECTING ELECTRICAL LOADS NO SENSITIVE EQUIPMENT LIKE COMPUTERS STEREOS TVS OR ANY PRODUCTS THAT CONSUME CLEAN POWER CHECK MANUFACTURER S PRODUCT MANUAL Page 3 Introduction Tsurumi s Operation Service and Repair Manual B SAFETY PRECAUTIONS WARNING e IN ORDER TO ASSURE SAFE AND EFFICIENT OPERATION OF THE GENERATOR OPERA TOR S SHOULD READ AND COMPLY WITH THE FOLLOWING SAFETY PRECAUTIONS Do not operate the generator near gasoline or gaseous fuels because of the potential dan ger from explosion or fire Do not fill the fuel tank with fuel while the engine is running Do not smoke or use open flame near the fuel tank Be careful not to spill fuel during refueling If fuel is spilled wipe it off and let it dry be
38. D BURNS TO NEARBY PERSONNEL NOTE e Do not disassemble the battery enclosure unit unless disassembly is required to gain access to the affected components Refer to exploded view in Replacement Parts section for parts information The item numbers in the following procedure are identical to those in the Replacement Parts exploded views The model TPG 7000H DXE generator has a 12 volt DC starting system Use a 12 volt garden tractor type battery as a replacement battery 1 Refer to Figure 21 or 22 Remove two wing nuts 79 and clips 78 Remove hold down plate 76 and two tie down rods 77 from battery base plate 74 2 Remove terminal fasteners from battery terminals 3 Remove battery from battery enclosure 4 Put replacement battery in battery enclosure 5 Place hold down plate 76 on battery being careful not to contact the battery terminals 6 Insert L shaped ends of tie down rods 77 in holes in plate 74 in base of battery enclo sure unit 7 Put threaded ends of tie down rods 77 in holes in hold down plate 76 Install clips 78 and wing nuts 79 on threaded rods to secure battery 8 Connect cables to terminals on the battery 9 Operate generator to verify that the battery is properly connected Removal Installation Page 40 Tsurumi s Operation Service and Repair Manual TT T8 T9 12 Volt Battery 76 74 77 Figure 21 Battery
39. DX TPG 7000H DXE 13 Front Cover to Engine Screws M8 ALL MODELS 8 7 10 1 11 8 13 7 120 140 14 Ground Wire to Rear Cover M3 TPG 2900H DX 1 5 2 2 2 0 2 9 20 30 M4 TPG 4300H DX 1 5 2 2 2 0 2 9 20 30 TPG 6000H DX TPG 7000H DXE 15 Rear Cover Bracket to Lower Muffler M12 TPG 4300H DX 21 7 28 9 29 4 39 2 300 400 Support Screw TPG 6000H DX TPG 7000H DXE 19 Muffler Support Bracket to Front Cover M8 TPG 2900H DX 8 7 10 8 11 8 13 7 120 140 Screw Muffler Support Bracket to Rear Cover M8 TPG 4300H DX 8 7 10 8 11 8 13 7 120 140 Screw TPG 6000H DX TPG 7000H DXE 21 Support Bar Screw M8 TPG 2900H DX 8 7 10 8 11 8 13 7 120 140 M6 TPG 4300H DX 8 7 10 8 11 8 13 7 120 140 TPG 6000H DX TPG 7000H DXE 25 Ground Wire to Frame Screw M5 ALL MODELS 2 9 3 3 3 9 4 4 40 45 26 Vibration Mount Flange Nut M8 ALL MODELS 8 7 10 8 11 8 13 7 120 140 Page 39 Removal Installation Tsurumi s Operation Service and Repair Manual A REPLACEMENT OF BATTERY WARNING DISCONNECT THE SPARK PLUG WIRE FROM THE SPARK PLUG BEFORE WORKING ON THE GENERATOR TO PREVENT INADVERTENT ENGINE START MAKE SURE THAT YOU DISCONNECT OR REMOVE THE BATTERY WHEN YOU DO MAIN TENANCE EXPLOSIVE HYDROGEN GAS MAY BE PRESENT AROUND THE BATTERY SPARKS FROM STATIC ELECTRICITY OR FROM HAND TOOLS CONTACTING BATTERY TERMINALS CAN CAUSE HYDROGEN GAS TO IGNITE CAUSING INJURY AN
40. E HEAVY STATOR APPROXIMATE LY 37 POUNDS NOTE Itis suggested that you have second person assist with stator removal While you tap upward with the hammer the other person should lift the stator from the front cover 9 Use a plastic rubber or other soft faced hammer to loosen the stator Tap upward on the side of the laminations Tap upward and alternate tapping the near side and far side of the stator until loosened enough to remove by hand 10 Put the removed stator away from the work area 11 Position the replacement stator 6 with the wires as shown in Figure 28 Put stator 6 over rotor 2 and against the front cover 1 12 Install stator cover 5 evenly over the stator 13 Align the bore in rear cover 7 with the rotor bearing 3 Position the rear cover 7 with the hole for flexible tube 12 aligned with the stator wires 14 Route the stator wires through the access hole in the rear cover 7 15 Slip the flexible tube 12 over the wires Put the flexible tube 12 in the wire access hole making sure the groove in the tube is seated in the lip of the wire access hole 16 Install cover bolts 8 and washer 9 Tighten bolts 8 in small increments and in an alter nating pattern Tighten the bolts so the stator cover is pulled down evenly against the relief at the edge of the front cover 1 and rear cover 7 17 Make sure the thin stator cover is seated all 360 degrees in the relief on both
41. E have a wiring access plate 5 11 12 Separate the flexible tube 12 from the rear cover 7 Pull generator wires out of the access opening in the rear cover 7 Disconnect engine wiring from the generator as required Remove four flanged bolts 21 to remove support bar 22 With engine and generator wiring disconnected the front panel can now be removed Remove four frame bolts 31 from front panel 29 Remove flanged nuts 26 from generator vibration mounts 27 2 Remove four flanged nuts 26 from four engine vibration mounts 27 Remove spacers 27 1 Lift the engine and generator assembly from the frame 28 using an overhead lifting device CAUTION Besure to protect the engine from damage Put cushioning material between the engine and the workbench Use wooden blocks to support the engine and generator assembly during removal and installation of generator components 13 Set engine and generator assembly on the workbench Position the assembly with the gen erator end facing up use support blocks to steady the assembly If you are replacing the stator 6 refer to Replacement of Generator Stator If you are replacing the rotor 2 refer to Replacement of Rotor If your are replacing the rotor bearing 3 refer to Replacement of Rotor Bearing If you are replacing the engine H 1 refer to Replacement of Engine Install front cover 1 with cooling slots down Align screw holes and insta
42. Enclosure Components B REMOVAL INSTALLATION OF BATTERY ENCLOSURE WARNING MAKE SURE THAT YOU DISCONNECT OR REMOVE THE BATTERY WHEN YOU DO MAIN TENANCE EXPLOSIVE HYDROGEN GAS MAY BE PRESENT AROUND THE BATTERY SPARKS FROM STATIC ELECTRICITY OR FROM HAND TOOLS CONTACTING BATTERY TERMINALS CAN CAUSE THE HYROGEN GAS TO IGNITE CAUSING INJURY AND BURNS TO NEARBY PERSONNEL NOTE Do not remove the battery enclosure unit unless required to gain access to other components If removal of the battery support is required remove according to the following procedures 1 Remove battery refer to Replacement of Battery section 2 Refer to Figure 22 Remove two bolt and washer assemblies 82 and two self locking nuts 83 from bottom of frame Then remove two bolt and washer assemblies 80 and two self locking nuts 81 from top of the frame 3 Remove entire battery enclosure unit and set aside for installation later NOTE Do not disassemble the battery enclosure unit any further unless disassembly is required to replace damaged battery enclosure components If necessary follow procedures beginning with step 4 4 Remove four bolt and washer assemblies 82 and four nuts 83 from base plate 74 5 Remove four bolt and washer assemblies 84 and four nuts 85 from shield plate 75 Page 41 Removal Installation 6 Tsurumi s Operation Service and Repair Manual 79 76 T 78 Figure 22 Bat
43. M 22 F020000590 Bar Support 2 H 26 Screw Upper Muffler 1 23 0011008020 Bolt Flanged M6 X 12 1 Support 24 E070000120 Brace Muffler Shield 1 H 34 Screw Brace to Shields 1 25 0011305008 Screw and Washer 1 NOTE Items prefixed with letter H are Honda Engine parts Assembly M5 X 8 NI Refer to Honda Parts Catalog for part numbers 25 1 F070000230 Cable Ground 1 26 0022008000 Nut Flanged M8 8 27 G060000482 Mount Vibration Isolator 2 Engine 27 1 G150000421 Spacer 2 27 2 G060000492 Mount Vibration Isolator 2 Generator 28 F011003191 Frame 1 29 C012011840 Front Panel Complete 1 Page 65 Replacement Parts Tsurumi s Operation Service and Repair Manual Exploded View Front Panel Model TPG 2900H DX Replacement Parts Page 66 Tsurumi s Operation Service and Repair Manual Parts List Front Panel Model TPG 2900H DX Ref Part Ref Part No Number Description Qty No Number Description Qty 30 C011017970 Front Panel less parts 1 64 C222000010 Condenser Holder 2 30 1 C011900180 Label 1 65 0011204010 Screw and Washer 2 31 0013006010 Bolt Frame M6 X 10 4 Assembly M4 X 10 32 C020004695 Control Box Complete 1 Ep reeressese ReeReSSUS 33 C021103243 Control Box less parts 1 esie sen ang 777 34 0014305012 Screw and Washer 4 DB Paar eS eStats aoe Assembly M5 X12 69
44. NEMA Ground Fault Circuit 20A 5 20R 5 20P Interrupter Up to NEMA NEMA 6 20 114208 L14 20P Locking Receptacle Up to NEMA NEMA 30A L5 30R L5 30P Locking Receptacle CAUTION The 120V duplex receptacle is protected by a GFCI Ground Fault Circuit Interrupter The GFCI shuts off the output current from the 120V duplex receptacle when a ground fault occurs in the generator or the appliance Please note that other receptacles are not protected by a GFCI B Dual Voltage Type 1 Select the voltage using the FULL POWER switch in accordance with the electrical appli ance Refer to Table 3 2 Operate the generator in the same way as step a through step c of single voltage type Page 19 Operating Instructions Tsurumi s Operation Service and Repair Manual Table 3 Available Receptacles With Full Power Switch On Switch Setting Lower Voltage Receptacle Higher Voltage Receptacle 120V Rated Output is Available Unavailable 120V 240V Half of Rate Output is Available Rated Output is Available WARNING TO TAKE OUT POWER FROM TWIST LOCK RECEPTACLE INSERT THE PLUG INTO RECEP TACLE AND TURN CLOCKWISE TO LOCK IT BESURE TO GROUND THE GENERATOR IF THE CONNECTED ELECTRICAL EQUIPMENT IS GROUNDED NOTE When the circuit breaker turns off during operation the generator is overloaded or the appliance is defective Stop the generator immediat
45. ONS e 4 o etx EE RE Du ER AR ORA NA eed eae 12 A Operating Controls AG SEE RE ex mes 12 B DC Circuit Controls e E WE eek Yum ket RON ORDER Aeg dor due 12 Check the Engine Oil Level 15 D Check Engine Fuel 2 92 an etre er nacen TR EE No ak ae domat 16 E Pre Start Checks oui m ee eee ehh el oad 17 F Starting and Operating the Engine 17 Using the Generator ee Ra 18 AG Applications aua o Detto Ce ea ee 18 Stopping the Generator 20 J enn p 21 K Idle CONTON cut gg eck po GR Teme eine ee E Qe 21 L Stopping tS ENJINS CC E m mn 21 M Wattage Information 21 4 Maintenance Mr a 23 Changing Engine pau cs deor t Ca b 24 Air Cleaner Servicen Rodi died e 24 C sediment Cup 25 D Cleaning and Adjusting Spark Plug 25 Models TPG 4300H DX TPG 6000H DX TPG 7000H DXE 5 Troubles ODIO ve dent aera mut SER REC ROSAS RUD e a nds 27 A Isolating Fault to the Generator or to the Co
46. Page C 3 Appendix C
47. ROM THE FRAME WITHOUT THE AID OF A LIFTING DEVICE NOTE e Refer to exploded view in Replacement Parts section for parts information The item numbers in the following procedure are identical to those in the Replacement Parts exploded views Tsurumi recommends that the heavy engine and generator assembly be removed from the frame before removing generator components The engine and generator wires have in line plug and socket connectors that can be disconnected to take electrical measurements or to allow component replacement Tag both ends of the wires as they are disconnected Write the wire color and or other characteristics such as color of stripe on the tag to assure the wires are properly reconnected Page 47 Removal Installation 2 3 4 NOTE Tsurumi s Operation Service and Repair Manual In order to gain access for removal of the generator and engine as a unit the fuel tank will first need to be drained and removed Refer to the procedures in Draining of the Fuel Tank and to Replacement of the Fuel Tank In addition the front panel and control box will need to be removed as covered in the pro cedures that follow Tag and disconnect engine wiring from the front panel 29 The engine wiring is in the cable that exits the control box 32 Remove two screws 11 from the generator brush cover 10 Tag and disconnect gener ator wiring Only Models TPG 4300H DX TPG 6000H DX and TPG 7000H DX
48. Repair Manual Parts List Front Panel Model TPG 4300H DX Ref Part Ref Part No Number Description Qty No Number Description Qty 30 C011017981 Front Panel less parts 1 64 C222000010 Condenser Holder 4 30 1 C011900180 Label 1 65 0011204010 Screw and Washer 4 31 0013006010 Bolt Flanged M6 X 10 4 Assembly M4 X 10 32 C020004706 Control Box Complete 1 66 0011204018 Screw and Washer 1 33 C021103684 Control Box Less Parts 1 Assembly M4 X 18 34 0014305012 Screw and Washer 4 BE esee em me patastin id Assembly 68 015815VB10 Diode Stack 1 M X 12 69 C150000250 Idle Control Unit 1 35 SW3116 Switch Engine Stop 1 70 0011204006 Screw and Washer 2 36 0013303008 Screw and Washer 2 Assembly M4 X 6 Assembly 71 secteeecd sereia EI M3 X 8 72 0321302509 Grommet 1 Sa aR a eg a ZAR 72 1 0321090509 Grommet 1 38 SW 3211 Switch Idle 1 72 2 0321201509 Grommet 1 39 0013303008 Screw and Lock Washer 2 Assembly M3 X 8 40 SW 3832 Switch Full Power 1 41 0013303008 Screw and Lock Washer 2 Assembly M3 X 8 42 GF53BKA Receptacle 120V GFCI 2 43 0022004000 Nut M4 4 AAS e 45 0013304010 Screw and Washer 4 Assembly M4 X 10 46 01401110G0 Pilot Light 1 47 0065605130 Receptacle 120V Twist 1 lock 48 0015130510 Screw and Washer 2 Assembly 6 32 X 10 49 0065706320 Receptacle 120V 240V
49. URUMI t9 TPG 4300H DX iP SEE l HONDA 2 AC 120V 2 6 LEGEND 1 Engine Switch 6 Ground Post 2 Idle Switch 7 Receptacle 120Vac 240Vac 3 Pilot Light 8 Receptacle 120Vac 4 Full Power Switch 9 Receptacle 120Vac GFI 2 5 14 Amp Circuit Breaker Figure 8 Model TPG 4300H DX Page 13 Operating Instructions Tsurumi s Operation Service and Repair Manual O 1 2 3 4 5 6 ENGINE IDLE PILOT FULL V BREAKER i DPD gu o lo e i usada O 1 i _ TSURUMI 6 low E E TPG 6000H DX GLEN NC A C G ah T 43 FHI R HONDA a a e 120V JAC12qV 240 i o 10 9 8 7 LEGEND 1 Engine Switch 6 20 Amp Circuit Breaker 2 Idle Switch 7 Ground Post 3 Pilot Light 8 Receptacle 120Vac 240Vac 4 Ful Power Switch 9 Receptacle 120Vac 5 30 Amp Circuit Breaker 10 Receptacle 120Vac GFI 2 Figure 9 Model TPG 6000H DX 1 2 3 4 5 6 9 ce _ TSURUMI TPG 7000H DXE i A C GENERATOR
50. Wrap electrical tape around the threads of a bolt to form a seal do not put tape on the first two threads of the bolt a For Models TPG 4300H DX TPG 6000H DX and TPG 7000H DXE use a 12mm 1 5 pitch bolt with a 25mm thread length b For Model TPG 2900H DX use a 10mm 1 5 pitch bolt with a 25 mm thread length Wind tape on bolt Figure 32 Wrapping Bolt with Tape NOTE Have shop towels available to wipe up spilled oil 8 Install the bolt in the center of the rotor shaft refer to Figure 33 Turn the bolt into the shaft the force required to turn the bolt will increase as the pressure increases Page 55 Removal Installation Tsurumi s Operation Service and Repair Manual ee Taped Bolt x eee ME ME I HEU Wii 1 d HI Figure 33 Tightening of Through Bolt for Separation of Engine and Generator 9 When the shafts separate place the rotor on a shop towel and let the oil drain from the shaft Wipe up oil that drained into the front cover 10 The front cover may remain installed unless it is damaged or the engine is being replaced To remove the front cover remove four bolt and washer assemblies 13 Figure 34 Engine To Generator Bolts 4 Figure 34 Front Cover Bolts 11 If the front cover was removed position front cover with cooling air slots on the bottom of the generator Secure with four bolt and washer assemb
51. and apply torque to the values shown in Table 10 Removal Installation Page 42 Tsurumi s Operation Service and Repair Manual H 22 Figure 23 Replacement of Muffler Models TPG 4300H DX TPG 6000H DX and TPG 7000H DXE D REPLACEMENT OF ENGINE MUFFLER MODEL TPG 2900H DX 1 Refer to Figure 24 Remove fasteners and muffler shields to expose the muffler 2 Disconnect muffler from engine exhaust connection 3 Remove screw H 26 from muffler support bracket 18 4 Remove inner shield H 23 and separate muffler from bracket 18 Page 43 Removal Installation Tsurumi s Operation Service and Repair Manual NOTE There are two attachment points on the muffler The lower support has a lip that fits into a slot in the bracket on the side of the generator The upper support has a screw hole for securing the muf fler to the generator bracket 18 H 22 Figure 24 Replacement of Muffler Model TPG 2900H DX 5 After removing screw H 26 lift the muffler so the lip clears the slot in the generator brack et Then move the muffler away from the generator bracket 6 Install inner shield H 16 and replacement muffler H 20 7 Install new exhaust flange gasket H 21 and connect exhaust flange to the muffler 8 Align upper screw hole in top of the muffler support with the screw hole in tab of generator bracket 18 Install screw H 26 9 Tighten fasteners to the torque values sh
52. and mercury lamps require 1 2 to 2 times the indicated wattage to start Electric motors require a large starting current Power requirements depend on the type of motor and its use Once enough surge is attained to start the motor the appliance will require only 5096 to 30 of the wattage to continue running CAUTION Check motor starting current and power factor carefully Most electrical tools require 1 2 to 3 times their wattage for running For example the 5 000 watts gen erated could power an 1800 watt to a 4000 watt electric drill Loads such as submersible pumps and air compressors require a very large force to start They need 3 to 5 times the wattage needed to maintain the tool in order to start For example a 5 000 watt gen erator would only be able to drive a 1 000 watt to 1 700 watt pump NOTE The wattage chart Table 4 is a guide only Refer to your specific appliance for correct wattage To determine the total wattage required for operating a particular electrical appliance or tool multiply the wattage figure of the appliance tool by the tool s amperage amps The voltage and amperage amps information can usually be found on a data plate or label which is normally attached to elec tric appliances and tools Table 4 Wattage Chart Applicable Wattage w Applicable Wattage W TPG 2900H DX TPG 4300H DX TPG 6000H DX TPG 7000H DXE 60 Hz 60 Hz 60 Hz 60 Hz Incandescent Lamp Heater 2000 33
53. anel and Control Box Disconnect wire from pilot light 46 Squeeze inward on tab to release the pilot light 46 from the panel 30 Install replacement pilot light 46 from front of panel Install pilot light 46 until the tab snaps into place Connect the wire to the pilot light 46 Install front panel 29 and control box 32 refer to Removal Installation of Front Panel and Control Box Circuit Breaker 51 Refer to Figure 36 Remove front panel 29 and control box 32 refer to Removal Installation of Front Panel and Control Box For breaker 51 remove two screw and washer assemblies 52 and washers 53 Disconnect wiring Connect wiring and install replacement breaker 51 in back of front panel 29 Secure with two screw and washer assemblies 52 and two washers 53 Circuit Breaker 54 b For breaker 54 remove four screw and washer assemblies 55 and washers 56 Disconnect wiring Page 59 Removal Installation Tsurumi s Operation Service and Repair Manual Figure 36 Front Panel and Control Box Components Model TPG 4300H DX Shown c Connect wiring and install replacement breaker 54 in back of front panel 29 Secure with two screw and washer assemblies 55 and two washers 56 d Install front panel 29 and control box 32 refer to Removal Installation of Front Panel and Control Box 10 Idle Control Switch Models TPG 4300H DX TPG 6000H DX
54. ated on a steep incline or slope In such a case the piston may seize it may seize even if the oil is above the upper level Do not operate in rain or with wet hands The operator may suffer severe electric shock if the generator is wet due to rain or snow If wet wipe dry well before starting Do not pour water direct ly over the generator nor wash it with water Do not connect the generator to a commercial power line Connection to a commercial power line may result in short circuit and damage the generator When connecting to domestic circuits install only approved transfer switches and make sure power and control circuitry meet local elec trical code requirements Do not smoke or use other smoking materials pipes cigars etc while handling the bat tery The battery emits flammable hydrogen gas which can explode if exposed to electric arcing or open flame Keep the work area well ventilated and keep the battery away from open flames sparks Introduction Page 4 Tsurumi s Operation Service and Repair Manual Honda Powered proven reliability quiet operation efficient fuel consumption Automatic Idle Control reduces fuel consumption noise and engine wear this feature is not available on Model TPG 2900H DX Large Silent Muffler with USDA qualified spark arrestor to significantly reduce noise The spark arrestor is designed to screen out hot sparks Large A
55. c d e Drain fuel from fuel tank refer to Draining of the Fuel Tank Remove two bolts 21 from support bar 22 on the muffler side of the generator Remove two bolts H 9 and washers H 10 from the fuel tank H 5 Slip the flange on the opposite side of the fuel tank out of the channel in the front panel 29 If the fuel tank is being replaced remove the fuel shutoff valve H 13 two rubber bushings H 12 and two bushings H 11 Removal Installation Page 46 Tsurumi s Operation Service and Repair Manual Installation of Fuel Tank 3 Install parts that were removed from the previously installed tank on the replacement tank b Slip the flange on the fuel tank into the channel on the back of the front panel 29 c d Install two bolts H 9 and washers H 10 to secure fuel tank Tighten fasteners Connect fuel tube from engine to fuel shutoff valve Drain tube H 13 amp Va J A WANT Fuel ZEISS Container YZ WYN pac e 20 5 N UN A Figure 26 Draining Fuel from Fuel Tank F REMOVAL INSTALLATION OF THE ENGINE AND GENERATOR AS A UNIT WARNING THE COMBINED WEIGHT OF THE ASSEMBLED ENGINE AND GENERATOR IS APPROXI MATELY 125 POUNDS USE OF AN OVERHEAD LIFTING DEVICE IS RECOMMENDED e INJURY TO MAINTENANCE PERSONNEL MAY RESULT FROM ATTEMPTING TO LIFT THE HEAVY ENGINE AND GENERATOR ASSEMBLY F
56. crankshaft is tapered and mates with a tapered bore in the rotor shaft The clamping force applied to the through bolt ties the rotor shaft to the engine crankshaft Cooling Fan Vibration Mounts Ball Bearing Through Bolt Figure 2 Cutaway of Generator Model TPG 2900H DX Shown Page 7 Description and Operation Tsurumi s Operation Service and Repair Manual 3 Description of the Engine NOTE Refer to the Honda engine Owner s Manual for Models GX160 GX240 GX340 and GX390 for addi tional coverage of the engine a The TPG 7000H DXE generator has an electric starter and a recoil starter All other generators are equipped with a recoil starter b The engine is equipped with an air filter to remove airborne contaminants from the engine inlet air c The engine is fitted with a muffler that provides quiet operation and controls the flow of engine exhaust gases The muffler is attached to the rear generator cover using a mounting bracket d The muffler for Models TPG 4300H DX TPG 6000H DX and TPG 7000 DX expels exhaust gases through a port in the side of the muffler The muffler for Model TPG 2900H DX has a smaller muffler that expels gases through a curved tube on the bot tom of the muffler e The muffler is fitted with a spark arrestor to screen out sparks ejected in the exhaust gases The spark arrestor for Models TPG 4300H DX TPG 6000H DX and TPG 7000 DX is installed in the exhaus
57. drawn through the carburetor into the engine Maintenance Page 24 Tsurumi s Operation Service and Repair Manual C SEDIMENT CUP CLEANING WARNING GASOLINE IS EXTREMELY FLAMMABLE AND IS EXPLOSIVE UNDER CERTAIN CONDI TIONS DO NOT SMOKE OR ALLOW FLAMES OR SPARKS IN THE AREA AFTER INSTALLING THE SEDIMENT CUP CHECK FOR LEAKS AND MAKE SURE THE AREA IS FREE OF RESIDUAL FUEL SPILLS OR SEEPAGE BEFORE STARTING THE ENGINE 1 Turn the fuel valve to OFF 2 Remove turn clockwise the sediment cup and O ring Wash both parts in nonflammable or high flash point solvent 3 Wipe the sediment cup and O ring dry then reinstall 4 Set the fuel shutoff valve Figure 18 to ON Check for leaks Figure 18 Fuel Shutoff Valve D CLEANING AND ADJUSTING SPARK PLUG Recommended spark plugs BPR6ES W20EPR U NIPPONDENSO To ensure proper engine operation the spark plug must be properly gapped and free of deposits 1 Remove the spark plug cap 2 Clean any dirt from around the spark plug base 3 Use the proper size spark plug wrench to remove the spark plug WARNING THE MUFFLER BECOMES VERY HOT DURING OPERATION AND REMAINS HOT FOR A WHILE AFTER STOPPING THE ENGINE BE CAREFUL NOT TO TOUCH THE MUFFLER WHILE IT IS HOT Page 25 Maintenance Tsurumi s Operation Service and Repair Manual 1 Visually inspect the spark plug Discard it if the insu
58. e Roo e Cof wa ee ee etd Quos 63 Appendix A Battery Enclosure Kit A 1 Appendix B Wheel Kit Model PGWK 100 B 1 Appendix C Wheel Kit Model PGWK 200 C 1 Tsurumi s Operation Service and Repair Manual 1 INTRODUCTION We thank you for purchasing a Tsurumi Generator We are sure that the generator you have selected will meet all your portable electric power needs This manual applies to the Tsurumi Generators listed below Specifications for the generators are pro vided in the SPECIFICATIONS section Key features of the generator are shown in the DESCRIPTION section TPG 2900H DX TPG 4300H DX TPG 6000H DX TPG 7000H DXE This manual provides instructions for operation service and repair of your generator We strongly rec ommend that those who operate the generator become familiar with the generator s features and con trols and read the operating instructions before using the generator The Operation Repair and Service Manual also provides instructions to service checkout and repair the generator This manual also provides replacement parts information Repair and service information for the Honda engine is provided in the Owner s Manual for Models GX160 GX240 GX340 and GX390 A copy of the Owner s Manual has been provided in the gener ator s literature package Parts information for the Honda En
59. e idle control unit DUAL VOLTAGE TYPE Check to make sure that the two output wires from the main coils pass through the coil on the idle control unit in the same direction 4 Check the idle control unit Check resistance between the five leads 5 Observe the terminal identification diagram below 6 Refer to Table 6 for resistance values NOTE The resistance readings in Table 6 will vary depending upon the type of circuit tester being used Table 6 is an example of the resistance readings measured by an ordinary analog circuit tester with a 1 5 volt battery power source It is advisable to check the resistance readings using your standard circuit tester and adjust the values accordingly Engine speed does Solenoid bracket not decrease when damaged or distorted load removed Check bend angle of solenoid bracket Correct as required Wire leads damaged Check to make sure two solenoid leads are securely connected Check wiring to idle control unit Check to make sure wire leads to the idle control unit are securely connected Solenoid failed Check resistance between two solenoid leads refer to Table 6 for resistance limits If resistance is higher or lower than limits replace solenoid Page 33 Troubleshooting Tsurumi s Operation Service and Repair Manual Table 8 Idle Control Unit Circuit Parameters Circuit Tester Power Source Apply Black Negative
60. e spark plug and cleaner element 12 Months Clean and adjust carburetor valve clearance and valve seat along with cylinder head 1 000 Hours e Inspect control panel parts 24 Months e Check rotor and stator e Replace engine mount rubber e Overhaul engine e Change fuel lines Page 23 Maintenance Tsurumi s Operation Service and Repair Manual A CHANGING ENGINE OIL 1 Drain the oil while the engine is still warm to assure rapid and complete draining 2 Remove the oil filler dipstick cap and drain plug 3 Allow oil to drain from the engine Figure 16 DRAIN PLUG Figure 16 Draining Engine Oil 4 Install the drain plug and tighten it securely 5 Refill with the recommended oil Figure 12 Check the oil level Install the oil filler dip stick cap Figure 17 NOTE Engine oil capacity 1 1 liters 1 16 U S Quart CAL FILLER CAP ADIPSTICK Figure 17 Checking Oil Level B AIR CLEANER SERVICE WARNING NEVER USE GASOLINE OR LOW FLASH POINT SOLVENTS FOR CLEANING THE AIR CLEANER ELEMENT A FIRE OR EXPLOSION COULD RESULT 1 A dirty air cleaner will restrict airflow to the carburetor To prevent carburetor malfunction service the air cleaner regularly Service more frequently when operating the engine in extremely dusty areas NOTE Neverrun the engine without the air cleaner Rapid engine wear will result from contaminants such as dust and dirt being
61. e the following refer to Figure 13 1 Make sure the engine is in a level position 2 Remove the oil filler cap dipstick and wipe it clean 3 Insert the filler cap dipstick into the oil filler neck but do not screw it in 4 Remove the filler cap dipstick and check the oil level 5 Ifthe level is low fill to the top of the oil filler neck with the recommended oil 6 Reinstall the oil filler cap dipstick GIL FILLER CAP ADIPSTICK UPPER LIMIT Figure 13 Checking Oil Level D CHECK ENGINE FUEL WARNING MAKE SURE YOU REVIEW EACH WARNING IN ORDER TO PREVENT FIRE HAZARD DO NOT REFILL TANK WHILE ENGINE IS RUNNING OR HOT CLOSE FUEL SHUT OFF VALVE BEFORE REFUELING WITH FUEL BE CAREFUL NOT TO GET DUST DIRT WATER OR OTHER FOREIGN OBJECTS INTO FUEL WIPE OFF SPILLED FUEL THOROUGHLY BEFORE STARTING ENGINE KEEP AWAY FROM OPEN FLAMES DO NOT USE SMOKING MATERIALS WHEN FILLING THE FUEL TANK DO NOT REFUEL WHILE SMOKING OR NEAR OPEN FLAME OR OTHER SUCH POTENTIAL FIRE HAZARDS OTHERWISE FIRE ACCIDENT MAY OCCUR AVOID REPEATED OR PROLONGED CONTACT WITH SKIN OR BREATHING OF VAPOR KEEP OUT OF REACH OF CHILDREN 1 Check fuel level at fuel level gauge refer to Figure 14 2 If fuel level is low refill with unleaded automotive gasoline 3 Fuel tank capacity TPG 2900H DX 2 9 gal TPG 4300H DX 4 5 gal TPG 6000H DX 4 5 gal TPG 7000H DXE 4 5 gal Operating Instructions Page 16 Tsurumi
62. ely check the appliance and or generator for overloading or defect and repair as necessary l STOPPING THE GENERATOR 1 2 3 4 Set the power switch to OFF or unplug the cord from the receptacle Move the throttle lever fully to the right Turn the engine switch to the OFF position Turn the fuel valve to the OFF position FUEL VALVE Figure 15 Fuel Valve Operating Instructions Page 20 Tsurumi s Operation Service and Repair Manual J OIL ALERT 1 The oil alert detects the fall in oil level in the crankcase and automatically stops the engine when the oil level falls down below the predetermined level 2 When the engine has stopped automatically check the oil level Refill engine oil to the upper level and restart the engine 3 If the engine does not start by usual starting procedures check the oil level K IDLE CONTROL TPG 4300H DX TPG 6000H DX AND TPG 7000H DXE The idle control feature automatically reduces engine speed when there is no load on the generator and automatically increases engine speed up to rated speed when load is applied The idle control feature provides fuel economy and low noise operation at no load running 1 How To Use Idle Control a Start the engine with IDLE switch set to OFF NOTE Warm up the engine without a load for a few minutes b Set IDLE switch to the ON position 2 Checking Idle Function a When the idle function does not operate normal
63. epair Manual 8 REPLACEMENT PARTS A INTRODUCTION This section provides exploded view illustrations that show the replacement parts for Tsurumi Portable Generators Models TPG 2900H DX TPG 4300H DX TPG 6000H DX and TPG 7000H DXE Also provided are parts listings that provide part number description and quantity The item numbers shown on the illustrations correspond with the item numbers in the facing parts listing B ORDERING PARTS Order replacement parts from Tsurumi America Inc 845 North Dillon Drive Wood Dale IL 60191 Tel 1 888 878 7864 Fax 1 630 766 6445 E mail info tsurumiamerica com Page 63 Replacement Parts Tsurumi s Operation Service and Repair Manual 29 See separate exploded view for parts breakdown H 22 Exploded View Generator Model TPG 2900H DX Replacement Parts Page 64 Tsurumi s Operation Service and Repair Manual Parts List Generator Model TPG 2900H DX Ref Part Ref Part No Number Description Qty No Number Description Qty 1 G010000790 Front Cover Generator 1 NOTE 1 Old rear cover G080000043 is no longer available When ordering replacement rear cover 7 order new rear 2 G020001201 Rotor C let 1 is a complete cover G080000080 and new muffler support bracket 18 3 0006203770 Bearing Ball 620322 1 E070000183 4 0013508245 Bolt Through M8 X 245 1 5 G120001202 Cover Stato
64. fore starting the engine Do not place flammable materials near the generator Be careful not to place fuel matches gunpowder oily cloths straw trash or any other combustibles near the generator Do not operate the generator inside a room cave tunnel or other insufficiently ventilated area Always operate the generator in a well ventilated area The engine may become overheat ed and the poisonous carbon monoxide gas contained in the exhaust gases will endanger human lives Keep the generator at least 1 meter 3 feet away from any structure or building during use When a generator is located close to a building or nearby equipment heat and exhaust from the engine will cause the surrounding temperature to rise This will degrade the engines cooling effi ciency causing overheating Do not enclose the generator nor cover it with a box The generator has a built in forced air cooling system and may become overheated if it is enclosed Operate the generator on a level surface It is not necessary to prepare a special foundation for the generator However the generator will vibrate on an irregular surface Therefore choose a level place without surface irregularities Shutoff the generator when moving the generator to another work site It the generator is tilt ed or moved during operation fuel may spill and or the generator may tip over causing a haz ardous situation Proper lubrication cannot be expected if the generator is oper
65. g 4 5 F100000011 Rod Hold down 2 13 0013706040 Bolt and Washer Assembly 4 6 F091000031 Clip 2 Shield to Tube 7 0021506000 Nut Wing 2 14 0022006000 Nut Self Locking 4 a Seesen Site 9 0013708020 Bolt and Washer Assembly 4 Tube to Frame M8X20L CHECK KIT CONTENTS Check to make sure the parts listed above are included in the kit Contact Tsurumi to obtain any miss ing parts ASSEMBLY OF BATTERY ENCLOSURE 1 Align holes in base plate 2 with holes in battery support tube 1 Install two bolts 9 and two nuts 10 2 Repeat step 1 for second battery support tube 1 3 Align holes in plate 3 with holes in battery support tubes 1 Install four bolts 13 and four nuts 14 Tighten all fasteners Appendix A Page A 2 Tsurumi s Operation Service and Repair Manual INSTALLATION OF BATTERY ENCLOSURE 1 Position assembled enclosure on crossover support on bottom of generator frame Install two bolts 11 through support tubes 1 and generator frame Install and tighten nuts 12 Align holes in support tubes 1 with holes in upper frame Install two bolts 13 and nuts 14 Check to make sure all bolts and nuts are tight CLIP SPRING WASHER AND WING NUT HOLD DOWN PLATE 4 INSTALLATION OF BATTERY 1 2 Set battery on base plate 2 Place hold down plate 4 on front edge of battery Install hooked end of tie down rods 5
66. gine is available in Honda s Parts Catalogs When there are differences between generator models separate instructions are provided The sep arate instructions are provided to make sure the correct procedures are used on the affected genera tors All information in the Tsurumi manuals is based upon the latest production configuration of the gener ator at the time of approval for printing If you have a problem with your generator that cannot be resolved using the Operation Repair and Service Manual or if you have questions about the operation service repair or maintenance of your generator contact your local Tsurumi generator dealer Page 1 Introduction Tsurumi s Operation Service and Repair Manual A PRECAUTIONS AND PLACARDS Pay special attention to precautionary notes preceded by the words WARNING CAUTION and NOTE WARNINGS indicate that there is a strong possibility of personal injury or loss of life if the procedure is not followed or if cleaning lubricating adhesives and other materials are not used properly CAUTIONS indicate that there is a possibility of equipment damage if instructions are not followed NOTES are used in procedures to provide additional or supplemental information to make the proce dure easier or more efficient WARNING THE GENERATOR IS DESIGNED TO GIVE SAFE AND DEPENDABLE SERVICE WHEN OPER ATED ACCORDING TO THE INSTRUCTIONS IN THE TECHNICAL MANUAL PROVIDED WITH THE GENERATOR
67. he event of a short circuit The breakers will trip when the circuit load exceeds the breaker s rated value The ground post is used to provide a positive ground for the generator The post has a wing nut to quickly connect a ground wire to the generator There are three types of receptacles one 120 Vac GFI protected receptacles two on most models one twist type 120 Vac receptacle and one 120 Vac 240 Vac combination receptacle B DC CIRCUIT CONTROLS 1 2 The circuitry for DC circuit consists of a 10 Amp fuse an overload protector and a re set switch In the event of an overload the overload protector will trip the reset switch refer to Figure 11 Operating Instructions Page 12 Tsurumi s Operation Service and Repair Manual A C GENERATOR i i HONDA IM MANUFACTURING CO LTD MADENUAPIN ENGINE PILOT BREAKER snum TPG 2900H DX 4 es o d AC 120V LEGEND 1 120 Vac Receptacle 4 18 Amp Circuit Breaker 2 Engine Switch 5 Ground Post 3 Pilot Light Figure 7 Model TPG 2900H DX o 1 2 3 4 5 o L C RUN amp 20 TS
68. if it fails the megger test Rotor fault Check rotor Remove generator rear cover and stator refer to COMPONENT REPLACEMENT for procedures Using a multimeter measure field coil resistance Measure resistance at the soldered terminals of the rotor and the core NOTE Because a diode is soldered to the coil ends at the terminals resistance may be measured only when the multimeter probes touch the terminals in one combination of polarity Therefore if no resistance reading appears try checking in reverse polarity 4 Using a megger tester check insulation resistance between the soldered terminal and the stator core Replace rotor if it does not meet the resistance values in Table 6 AC voltage too high or too low Engine speed too high or too low Check engine speed Operate the generator with no load applied on the generator If the speed is too high or too low adjust throttle adjustment screw to set engine speed as specified in Table 6 Total wattage applied by appliances lights power tools etc exceeds generator s rated load Calculate generator load Calculate total wattage being applied to the generator rated load of each connected power consuming device times the power factor of the device Disconnect power consuming device s as required to reduce total wattage to the level shown on the generator data placard Troubleshooting Page 30 Tsu
69. il from engine and drain fuel from fuel tank to avoid spillage during installation of the wheel kit refer to Tsurumi Operation Service and Repair Manual for draining instructions Page B 2 Appendix B Tsurumi s Operation Service and Repair Manual INSTALL AXLE ON GENERATOR 1 2 Position portable generator frame on end engine downward and generator upward Place a clamp 8 on the frame cross member Use clamp 8 as a template and mark center of the holes in clamp 8 with a center punch Use the center punch dimple as a guide and drill two 3 8 inch holes through the frame cross mem ber as shown in View A Repeat step 2 and 3 for the second set of axle clamp holes Place axle 7 on frame cross member Install two axle clamps 8 over axle 7 and secure with screws 5 and nuts 6 Before tightening screws make sure axle extends an equal amount from the sides of the generator frame Tighten nuts 6 INSTALL AXLE ON TRASH PUMP 1 2 Position pump frame on end engine downward and pump upward Position a U bolt plate 12 to the frame cross member Use plate 12 as a template and mark cen ter of the holes with center punch Use the center punch dimple as a guide and drill two 3 8 inch holes through the frame cross mem ber as shown in View A Repeat steps 2 and 3 for the second set of U bolt holes Place axle 7 on frame cross member Install U bolts 11 over the axle 7 Put plate 12 over threaded
70. iliarize your self with the layout of the front panel for your generator before operating the generator a The operating controls switches lights electrical receptacles and circuit breakers for the generator are mounted on the front panel b Acontrol box is mounted on the back of the front panel The control box contains the idle control unit diode condensers and dc reset pushbutton switch refer to Figure 11 Description and Operation Page 8 Tsurumi s Operation Service and Repair Manual c d The engine starter and control wiring exits through a hole in the side of the control box The diode and fuse that are part of the DC circuit are located inside the control box The generator leads and control wiring are connected inside the control box A flexible rubber sleeve provides protection for the generator wiring B FUNCTIONAL DESCRIPTION 1 Generation of No Load Voltage refer to Figure 3 b When the generator rotor begins to rotate the permanent magnet in the rotor gener ates 3 to 6 volts alternating current in the main coil and in the condenser coil windings The low voltage generated in the condenser coil also generates minute current flow a through the condenser coil At the same time low level magnetic flux intensifies at the rotor s magnetic pole As the magnetic force intensifies voltage increases in the main coil and in the condenser coil As current a increases magnetic flux
71. ion Service and Repair Manual O FH N EEN Rs ar fi c5 os 55 56 z a 48 50 52 53 45 Exploded View Front Panel Model TPG 7000H DXE Page 78 Replacement Parts Tsurumi s Operation Service and Repair Manual Parts List Front Panel Model TPG 7000H DXE Ref Part Ref Part No Number Description Qty No Number Description Qty 30 C011018001 Front Panel less parts 1 68 015815VB20 Diode Stack 1 30 1 C011900180 Label 1 69 C150000250 Idle Control Unit 1 31 0013006010 Bolt Flanged M6 X 10 4 70 0011204006 Screw and Washer Assembly 2 32 C020007853 Control Box Complete 1 M4 X 6 33 C021103684 Control Box Less Parts 1 72 0321302509 Grommet 1 34 0014305012 Screw and Washer Assembly 4 72 1 0321090509 Grommet Not Shown 1 M5 X 12 apy eega Ref Part M aea 2v No Number Description Qty 37 H 27 Key Switch Engine 1 38 SW 3211 Switch Idle 1 H 28 Nut Ring Part of 35 1 39 0013303008 Screw and Lock Washer 2 H 29 Washer Fiber Part of 35 1 Assembly M3 X 8 H 30 Reset Switch 1 40 SW 3832 Switch Full Power 1 H 31 2 222222 Screw 2 41 0013303008 Screw and Lock Washer 2 H 32 Fuse Holder with Fuse 15A 1 Assembly M3 X 8 H 33 Overload Protector 1 42 GFS3BKA Receptacle 120V GFCI 2 NOTE Items p
72. ir Filter for superior emission control Large Capacity Fuel Tank with Fuel Gauge for extended run time Rubber Vibration Pads isolates generator engine vibration from the frame for maximum pro tection and noise reduction Ground Fault Circuit Interrupter GFCI on 120V duplex receptacle protects operator from shock Full Power Switch allows voltage selection either full rated output from 120V receptacle or half rated output from 120V receptacle and full rated output from 240V receptacles this feature is not available on Model TPG 2900H DX Circuit Breaker protects generator from overload damage can be reset with the flip of a switch no fuse to replace 100 Copper Windings for long life MODELS TPG 2900H DX TPG 4300H DX TPG 6000H DX TPG 7000H DXE Max Rated Output WATTS 2900 2200 4300 3300 6000 4700 7000 5500 Max Rated Current at 120V Amps 22 5 18 3 amp 31 7 27 5 amp 45 8 39 2 amp 54 2 45 8 amp at 240V 15 8 13 8 22 9 19 6 27 1 22 9 5 Voltage Volts 120V 60 Hz 1 6 120V 240V 120V 240V 120V 240V 60 Hz 1 60 Hz 1 60 Hz 1 AC Outlet Receptacles 1 5 20 2 5 20 2 5 20 2 Duplex 20A 120V 20 120V w GFCI 20A 120V w GFCI wIGFCI 1 NEMA L5 30R 1 NEMA L5 30R 30A 120V Twist Lock 30A 120V Twist Lock 1 NEMA L14 20R 20A 1 NEMA L14 20R 120 240V Twist Lock 20A 120 240V Twist Lock
73. its products No other warranty expressed or implied is authorized by or applicable to the seller No person agent or dealer is authorized to enlarge upon this warranty TSURUMI expressly disclaims liability for consequential or incidental damages or breach of expressed or implied warranty and any implied warrant of fitness for a particular purpose and merchantability shall be limited to the duration of the expressed warranty Some states do not allow limitations on the duration of an implied warranty so the above limitation or exclusion may not apply to you Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation of exclusion may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state Tsurumi Manufacturing Co Ltd TABLE OF CONTENTS Section Title Page 1 DET oec io inh inne wie le eae petet eR be RR Ede ERES A Precautions and Placards 2 B Safety Precautions uk uua Adee POG eee ete te twa oot dee rdg duos 4 C Specifications Key 5 2 Description and Operation ee 6 A Physical Description RT ER Rex xx V PERPE 6 B Functional Description 9 3 Operating INSUUGH
74. justable pipe frame width is 330mm 530mm 6 Attach the axle assembly at an optional position in or der to prevent contact with other parts 2 Place the axle assembly A underneath the frame B See Fig 3 and attach the axle assembly to the bottom 8 Tighten bolts with the proper torque 78 95 Ibf m of the frame with two U bolts nuts and washers 8 8 10 8 N m 3 Use two short U bolts two nuts two washers tose 9 Next install each tire with the 4 bolts amp nuts facing each cure each axle assembly to the bottom of the frame other to the inside Therefore the hubcap should face the outside 4 There are 8 holes in each axle assembly for use with the Par U bolts Use 4 holes to secure each axle assembly to the 10 Insert the cotter pins into the axle hole and bend the pipe frame end of each cotter pins with pliers to secure the tires in place Bolt amp Nut Fig 3 Outside Step 2 Install Handles 1 Carefully stabilize the generator or pump unit and install handles near the engine side C by placing each handle on the bottom pipe frame Then attach the handle to the pipe frame with the two U bolts D and the two handle brackets See Fig 4 2 Use the two long U bolts two nuts and two washers to secure each handle bracket to the frame Tighten bolts with the proper torque 78 95 Ibf m 8 8 10 8 N m
75. lator is cracked or chipped Clean the spark plug with a wire brush if it is to be reused 2 Measure the plug gap with a feeler gauge Adjust the gap as necessary by bending the side electrode Figure 19 4 0 7 0 8 mm 0 028 20 031 in Figure 19 Spark Plug Gap 3 The gap should be 0 7 0 8 mm 0 028 0 031 inch as shown Maintenance Page 26 Tsurumi s Operation Service and Repair Manual 5 TROUBLESHOOTING The procedures that follow together with the fault isolation tables can be used as a guide to isolate gen erator faults Refer to these procedures when the engine fails to start after several attempts or when electricity is not available at the receptacles Before testing generator components determine if the failure is located in the generator head or in the control panel Do this by following the instructions below If after following these procedures your generator fails to start or generate electricity contact the near est Tsurumi generator dealer A ISOLATING FAULT TO THE GENERATOR OR TO THE CONTROL PANEL 1 2 3 4 This unit uses permanent magnets built into the rotor for initial excitation Do not flash the fields to try to re excite the field Isolate the defect by disconnecting the red white black and blue wires from the stator do not disconnect the two yellow wires Then measure the AC voltage of each AC coil Check for 120 vac X596 from the red white wires
76. lies 13 Tighten to the torque val ues shown in Table 10 12 Complete assembly of the generator as follows a Install rotor 2 Refer to Replacement of Rotor for rotor installation procedures b If bearing 3 was removed install according to the bearing installation procedures in Replacement of Rotor Bearing c Install the stator 6 stator cover 5 and rear cover Refer to Replacement of Generator Stator for installation procedures Removal Installation Page 56 Tsurumi s Operation Service and Repair Manual J REPLACEMENT OF FRONT PANEL COMPONENTS 1 Removal Installation of Front Panel and Control Box NOTE Toease the replacement of components drain and remove the fuel tank and remove the front panel and or control box 32 from the frame a Refer to Figure 35 Remove four screw and washer assemblies 34 to separate con trol box 32 from front panel 29 b Disconnect flexible tube 12 from rear cover 7 c Tag and disconnect generator wires Pull generator wires free from the control box 32 CAUTION Carefully remove the front panel from the frame to avoid damage to wiring and or electrical or electronic components Use care to avoid damage by the wire loop that passes through the coil on the idle control unit d Remove four frame bolts 31 at the corners of the front panel 29 Separate the front panel 29 from the frame e Replace panel mounted or control box mou
77. ll four bolt and washer assemblies 13 Tighten bolt and washer assemblies 13 to the torque values shown in Table 10 Removal Installation Page 48 Tsurumi s Operation Service and Repair Manual NOTE Model TPG 2900H DX uses four vibration mounts of two different part numbers Two vibration mounts of one part number are used to support the generator Two vibration mounts of another part number are used to support the engine Refer to the Replacement Parts section for part numbers and location Model TPG 4300H DX uses six vibration mounts of the same part number to support both the engine and the generator Refer to the Replacement Parts section for part numbers and location Models TPG 6000H DX and TPG 7000H DXE use six vibration mounts of two different part num bers Two vibration mounts of one part number are used to support the generator Four vibration mounts of another part number are used to support the engine Refer to the Replacement Parts section for part numbers and location 20 21 22 23 24 NOTE If vibration mounts 27 and 27 2 are being replaced first install the mounts on frame 28 as follows a Install engine vibration mounts 27 and secure to frame 28 with flanged nuts 26 b Install generator vibration mounts 27 2 and secure to frame 28 with flanged nuts 26 c When used install two spacers 27 1 over the two generator vibration mounts 27 2 Install assembled e
78. ly please check the following NOTE Most induction loads such as an electric motor require wattage three to five times larger than their rating at starting This starting wattage should not exceed the rated output of the generator b Is the generator overloaded Make sure that the generator is not overloaded c Turn the IDLE switch off when the idle control does not work normally under the rated output L STOPPING THE ENGINE 1 Turn off the switch of load or disconnect the load 2 Turn the IDLE switch off 3 Push ENGINE to stop NOTE Allow the engine about 3 minutes to cool down at no load before stopping M WATTAGE INFORMATION When starting some appliances a surge of energy occurs Depending upon the nature of the elec trical load the amount of electrical power needed to start the appliance may exceed the amount need ed to maintain its use See Table 4 for appliances you may use with this generator Electrical appliances and tools normally come with a label indicating voltage cycles Hz amperage amps and electrical power needed to run the appliance or tool Check with your nearest dealer with questions regarding power surge of certain appliances or power tools Page 21 Operating Instructions Tsurumi s Operation Service and Repair Manual Electrical loads such as incandescent lamps and hot plates require the same wattage to start as need ed to maintain use Loads such as fluorescent
79. ngine and generator as a unit over vibration mounts 27 and 27 2 Install flanged nuts 26 on the engine vibration mounts 27 Connect engine wiring from the front panel 29 according to the tags attached to the wires during disassembly The engine wiring is in the cable that exits the control box 32 Install the brush cover 10 and secure with two screws 11 Awiring access cover brush cover is provided only on Models TPG 4300H DX TPG 6000H DX and TPG 7000H DXE 25 26 27 28 Slip the flexible tube 12 in the hole in the rear cover 7 making sure the groove in the tube is seated in the hole in control box 32 and rear cover 7 Connect engine wiring to the generator as required Refer to the Wiring Diagrams section Install front panel and control box see Removal Installation of Front Panel and Control Box fuel tank see Replacement of Fuel Tank and engine muffler see Replacement of Engine Muffler Install four flanged bolts 21 to secure support bars 22 Page 49 Removal Installation Tsurumi s Operation Service and Repair Manual Figure 27 Removal of Engine and Generator as a Unit Removal Installation Page 50 Tsurumi s Operation Service and Repair Manual G REPLACEMENT OF GENERATOR STATOR NOTE Refer to exploded view in Replacement Parts section for parts information The item numbers in the following procedure are identical to those in the Replacement Pa
80. nted components as applicable f After replacing the panel mounted component connect generator and engine wires using the tags as a guide Install control box 32 on front panel 29 and secure with screw and washer assemblies 34 g Install front panel 29 on frame and secure with four frame bolts 31 2 Reset Pushbutton TPG 7000H DXE Only a Refer to Figure 35 Remove front panel 29 and control box 32 refer to Removal Installation of Front Panel and Control Box b Disconnect wiring c Remove screws H 31 and pushbutton H 30 d Install replacement pushbutton H 30 and secure with screws H 31 e Connect wiring f Install front panel 29 and control box 32 refer to Removal Installation of Front Panel and Control Box Page 57 Removal Installation Tsurumi s Operation Service and Repair Manual Figure 35 Front Panel and Control Box Components Model TPG 7000H DXE Shown 3 Overload Protector TPG 7000H DXE a Refer to Figure 35 Remove front panel 29 and control box 32 refer to Removal Installation of Front Panel and Control Box b Remove overload protector H 33 from its connector c Install replacement overload protector H 33 in its connector d Install front panel 29 and control box 32 refer to Removal Installation of Front Panel and Control Box 4 DC Fuse TPG 7000H DXE a Refer to Figure 35 Remove front panel 29 and control box 32 refer to
81. ntrol Panel 27 B Measuring Insulation Resistance 27 C Electrical Limits Reference Chart liliis 28 D Troubleshooting Charts 29 E Wining DIAG FARIS unio MINS He E gm AA EE a 35 6 Remov l lnstallation 24 dor eae soe POSE aE 1520 55 1 39 A Replacement of Battery ne hte e te RR RC eR Re ecd 40 B Removal Installation of Battery Enclosure 41 C Replacement of Engine Muffler 42 Models TPG 4300H DX TPG 6000H DX TPG 7000H DXE D Replacement of Engine Muffler 43 Model TPG 2900H DX E Replacement of Fuel Tank 45 F Removal Installation of Engine and Generator as a Unit 47 G Replacement of Generator Stator 51 H Replacement of Rotor 52 Replacement of Rotor eee eee 53 J Replacement of Front Panel Components 57 T Storage Instraellons oe Sia odere a a s OR e Reb a y SS t Rc 62 8 Replacement Parts 5 irure E SES 63 A Introductions uS ach IR ee tUe RR Ped ple REND REC a OR deett 63 B Ordering Parts sese ao sus ek es
82. own in Table 10 Removal Installation Page 44 Tsurumi s Operation Service and Repair Manual E REPLACEMENT OF FUEL TANK WARNING DO NOT DRAIN FUEL WHILE SMOKING OR WHILE IN CLOSE PROXIMITY TO OPEN FLAME ENGINE FUEL GASOLINE IS HIGHLY FLAMMABLE AND IF ACCIDENTALLY IGNITED CAN CAUSE SEVERE BURNS AND DEATH MAKE SURE THAT YOU DISCONNECT OR REMOVE THE BATTERY BEFORE DRAINING FUEL OR ANYTIME MAINTENANCE WILL INVOLVE HANDLING ENGINE FUEL ENGINE FUEL IS EXTREMELY FLAMMABLE AND CAN CAUSE SEVERE OR FATAL BURNS IF IGNITED MAKE SURE THAT YOU DISCONNECT OR REMOVE THE BATTERY WHEN YOU DO MAIN TENANCE EXPLOSIVE HYDROGEN GAS MAY BE PRESENT AROUND THE BATTERY AND CAN BE IGNITED BY STATIC ELECTRICITY OR BY CONTACT WITH THE BATTERY TERMI NALS BE SURE TO FOLLOW LOCAL GASOLINE HANDLING TRANSPORT AND FUEL DISPOSAL REGULATIONS 1 Draining the Fuel Tank Itis not necessary to drain the engine fuel tank for the majority of routine maintenance tasks However the tank should be drained anytime the generator will be stored or when the fuel tank must be removed for maintenance b Ifthe engine can be started start the engine and close the fuel tank shutoff valve H 13 refer to Figure 25 Let the engine operate until it is starved of fuel and stops By doing so residual fuel in the fuel lines and carburetor will be reduced to a minimum c Disconnect the fuel hose from the fuel tank shutoff valve H 13 refer to Figure 26 d
83. r up to 30A if the rated current is over 30A and Rec 1 is available up to 15A When the full power switch is set for double voltage indication 110V 220V or 120V 240V the switch position is indicated by the upper dotted line in Figure 8 e Refer to Figure 6 for a simplified diagram of the circuit The two main coils are shown connected in series In this example power is simultaneously available from the receptacles for both voltages Higher voltage receptacle Rec 3 has power available up to rated power however Rec 1 and Rec 2 for the lower voltage can output only up to the rated power of each receptacle f Table 1 summarizes in tabular form the power available or not available depending upon the position of the full power switch Description and Operation Page 10 Tsurumi s Operation Service and Repair Manual 120V or 110V Figure 5 Full Power Switch Set for Single Voltage Output 3 1 5 120V P 110V j MC2 Rec 2 iid Rec 3 240V 220V Figure 6 Full Power Switch Set for Dual Voltage Output Table 1 Full Power Switch Switch Setting Versus Output Available Switch Lower Voltage Higher Voltage Position Receptacle Receptacles 110V Rated No Output or 120V Output Can Be Taken 110V 120V Half of Rated Rated or 120V 240V Output Output Page 11 Description and Operation
84. r 1 Ref Part 6 G040005812 Stator 1 No Number Description Qty 7 G080000800 Rear Cover Generator 1 H 1 GX160K1VED2 Engine Honda 1 Note 1 H 2 Clamp Fuel Tube 1 8 0012506110 Bolt Cover M6 X 110 3 H 3 Bolt Exhaust Flange 2 9 0030306000 Washer Spring M6 3 H 4 Gasket Exhaust Flange 1 105 i Geese eee peat sees Pas H 5 Fuel Tank 1 T4 eae AE H 6 Cushion 2 12 G070000130 Tube Flexible 1 H 7 Cap Filler 1 13 0013708020 Bolt and Washer 4 HE8s Screen Fuel 1 Assembly Front Cover M8 X BO Bolt 2 20 H 10 Washer Flat 2 14 0011203006 Screw and Washer 1 H 11 Bushing Steel 2 Assembly M3 X 6 H 12 Bushing Rubber 2 14 1 C190000950 Wire Ground Not 1 13 Valve Fuel Shutoff 1 Shown 15 H 14 Seal Sediment Cup 1 E CREE Ed 7 H 16 Shield Inner 1 H 17 Seal 2 17 H 18 Nut 2 18 E070000183 Bracket Muffler Support 1 Note 1 H 19 Support Muffler 1 19 0013708020 Bolt and Washer 1 FEAT esses Gasket Exhaust Flange 1 Assembly Bracket to H 22 Shield Outer Muffler 1 Rear Cover M8 X 20 HA Woes Bolt Flanged Muffler 8 20 Shield 21 0013006010 Bolt Flanged M6 x 10 4 H 24 Spark Arrestor 1 Support Bar Mosa recien
85. refixed with letter H are Honda Engine parts 43 0022004000 Nut 4 Refer to Honda Parts Catalog for part numbers 44 45 0013304010 Screw and Washer 4 X 10 4 46 0140111060 Pilot Light 1 47 0065605130 Receptacle 120V Twist lock 1 48 0015130510 Screw and Washer Assembly 2 6 32 X 10 49 0065906330 Receptacle 120V 240V 1 Twist lock 50 0015130510 Screw and Washer Assembly 2 6 32 X 10 51 IEGBX630 Breaker 1 52 0015130510 Screw and Washer Assembly 2 6 32 X 10 53 N A Washer Flat see 52 2 54 IEGBX6622 Breaker 1 55 0015130510 Screw and Washer Assembly 4 6 32 X 10 56 N A Washer Flat see 55 4 57 0021805000 Wing Nut M5 1 58 0030405000 Washer Spring M5 Ni 2 59 0021905000 Nut Hex M5 Ni 1 60 0030105000 Washer Flat M5 Ni 1 61 0030705000 Washer Lock M5 Ni 1 62 0010205015 Screw Grounding 1 M5 X 15Ni 63 C220000530 Condenser Set 2 per set 1 64 C222000010 Condenser Holder 4 65 0011204010 Screw and Washer Assembly 4 M4 X 10 66 0011204018 Screw and Washer Assembly 1 M4 X 18 67 Page 79 Replacement Parts Parts List Battery Enclosure Model TPG 7000H DXE Parts List Battery Enclosure Model TPG 7000H DXE Tsurumi s Operation Service and Repair Manual p79 T T78 Ref Part No Number Description Qty FU11003215 Pipe Frame Unit Electric 1 Complete Not Shown 73 F200000260 Tube Battery S
86. rts exploded views 1 Drain and remove fuel tank H 5 refer to Replacement of Fuel Tank for removal instruc tions 2 Remove the muffler H 20 and shields to gain access to generator refer to Replacement of Muffler for removal instructions 3 Remove muffler support bracket 18 Figure 23 as follows a For Model TPG 2900H DX Remove bolt and washer assembly 19 Figure 24 Remove flanged nut 26 securing bracket 18 to rear cover 7 b For Model TPG 4300H DX TPG 6000H DX and TPG 7000H DXE Remove two bolt and washer assemblies 19 Figure 23 securing bracket 18 to rear cover 7 4 Remove the flexible tube 12 Figure 28 from the rear cover 7 Pull the wires out of the access opening in the rear cover Tag and disconnect the wires Figure 28 Replacement of Stator 5 Remove bolts 8 and washers 9 Use a plastic rubber or other soft faced hammer to loosen the rear cover 7 Alternately tap upward on the generator mounting lugs until the rear cover can be removed by hand 6 With the rear cover loosened carefully position the rear cover so you have access to ground screw and washer assembly 14 Page 51 Removal Installation Tsurumi s Operation Service and Repair Manual 7 Remove screw and washer assembly 14 from the lug of the ground wire Separate the rear cover 7 from the generator 8 Remove the stator cover 5 WARNING TO AVOID BEING INJURED BE PREPARED TO LIFT TH
87. rumi s Operation Service and Repair Manual FAULT PROBABLE CAUSE REMEDY AC voltage is Engine speed too low normal at no load continued but load can not be applied continued Check engine speed Operate the generator at no load If the speed is too low adjust to the normal engine speed specified in Table 6 7 Restart the generator and apply load If load still can not be applied check stator rotor and condensers refer to No AC Output troubleshooting steps above Faulty power consuming device Check for faulty appliance power tool or other power consuming devices Engine overheated Check for and clear away debris covering engine and generator cooling air inlets and outlets Failed generator insulation 1 Check Insulation 2 Stop engine Measure the insulation resistance between the live terminal of a receptacle and the ground post on the front panel 3 Ifthe insulation resistance is less than 1 disassemble the generator to obtain the stator and rotor 4 Disassemble to gain access to the components in the control box 5 Check the insulation resistance of the stator the rotor and the live electrical components in the control box Any component whose insulation resistance is less than 1MO is faulty and may cause electrical leakage 6 Replace any component having insulation resistance of less than 1MO No DC output Condenser stator or rotor fault
88. s Operation Service and Repair Manual EMPTY Figure 14 Fuel Gauge Indications E PRE START CHECKS WARNING MAKE SURE YOU REVIEW EACH WARNING IN ORDER TO PREVENT FIRE HAZARD KEEP AREA CLEAR OF FLAMMABLES OR OTHER HAZARDOUS MATERIALS 1 Check the following items before starting the engine a Fuel leakage from fuel hose etc b Bolts and nuts for looseness c Components for damage or breakage 2 Check generator surroundings a Keep generator at least 3 feet 1 meter away from buildings or other structures b Only operate generator in a dry well ventilated area c Keep exhaust pipe clear of foreign objects d Keep generator away from open flame e Keep generator on a stable and level surface f not block generator air vents with paper or other material F STARTING amp OPERATING THE ENGINE 1 Before starting the engine set AC circuit breakers to OFF 2 Refer to the Honda engine owner s manual a Turn the fuel valve to the ON position b Move the choke lever to the CLOSE position Page 17 Operating Instructions Tsurumi s Operation Service and Repair Manual NOTE The choke may not be needed if the engine is warm or the air temperature is high 3 Move the throttle lever slightly to the left 4 MODEL TPG 7000H DXE ONLY To start the engine using the electric starter proceed as follows a Turn key in engine START STOP switch b Turn key fully right to START position Hold
89. sover plates that form the base of the tubular frame Vibration isolators support the generator and engine unit The isolators are fitted with threaded studs that secure the generator and engine unit to the frame Description of Generator b c d e h The generator consists of a rear cover stator cover stator rotor and front cover The front cover of the generator attaches to the engine and forms the generator to engine interface The front cover has a series of slots that allow entry of cooling air into the generator A fan on the rotor circulates air through the generator The rear cover has mounting lugs that are the generator to frame attachment points The rear cover supports a ball bearing at the back end of the generator rotor The rear cover has a removable access plate to provide access to the stator wiring an access plate is not used on Model TPG 2900H DX The rotor consists of a shaft a stack of steel laminations and copper wire windings Components mounted on the rotor include a diode a surge absorber two permanent magnets and a cooling air fan The windings and the laminated steel core form the field coil The permanent mag nets are used to induce voltage in the main coil of the stator The diode and the surge absorber are located under the rotor windings at the bearing end of the rotor shaft The rotor is attached to the engine crankshaft with a through bolt tie bolt The engine
90. t port of the muffler The spark arrestor for Model TPG 2900H DX is installed in the inlet side of the muffler f engine has an oil filler plug that is used to check engine oil level Engine oil is added through the same filler plug port The engine oil drain plug is installed in the engine casing adjacent to the oil filler plug g The engine has a carburetor choke control for starting the engine during cold weath er operation Models TPG 4300H DX TPG 6000H DX and TPG 7000H DXE have a ring type choke control Model TPG 2900H DX has a choke lever 4 Description of the Fuel Tank a The fuel tank is attached to one side of the frame by two cushioned mounts The tank is supported on the opposite side by cushioned pads that fit into a channel on the backside of the front panel b Ascreen is provided under the filler cap to prevent entry of large contaminants c The tank has a fuel shutoff valve that is used to prevent fuel spillage when the gen erator is not in use The fuel shutoff valve is used to drain fuel from the tank if need ed for replacement of generator components The fuel shutoff valve should be closed during transport to prevent fuel spillage d The fuel shutoff valve has a sediment bowl to capture heavier contaminants that may have passed through the fuel tank filler screen 5 Description of the Front Panel NOTE Refer to Figure 7 through Figure 10 for illustrations of the generator front panels Fam
91. ter goes out or its normal scale it shows resistance to some extent When results of the checking indicates failure even in one section replace with a new diode Troubleshooting Page 34 Tsurumi s Operation Service and Repair Manual E WIRING DIAGRAMS CONTROL BOX ENGINE S SW OS UNL 459 1 i ENGINE NFB BLACK s N O Q D MCI E sue FC H G Au Emp 9 SC WHITE WHITE Ne YELLOW ET YELLOW Wiring Diagram Model TPG 2900H DX Page 35 Troubleshooting Tsurumi s Operation Service and Repair Manual ENGINE CONTROL BOX GREEN WHITE F C Sout GREEN S SW mo UL 41556 ite 1
92. tery Enclosure Exploded View Perform repair and or maintenance then proceed as follows a Align screw holes in battery base plate 74 with holes in support tubes 73 Install and tighten four bolt and washer assemblies 82 and four nuts 83 b Align screw holes in battery shield plate 75 with holes in support tubes 73 Install and tighten four bolt and washer assemblies 84 and four nuts 85 REPLACEMENT OF ENGINE MUFFLER Models TPG 4300H DX TPG 6000H DX and TPG 7000H DXE 2 3 A 5 6 x 7 8 9 Refer to Figure 23 Disconnect muffler from engine exhaust connection Remove screw H 26 securing the muffler to support bracket 18 Remove inner shield H 23 and separate muffler from bracket 18 Remove spacer H 37 from the muffler support bracket 18 Install shield H 23 and replacement muffler H 20 Install spacer H 37 between the lugs of the support bracket 18 Use a probe such as a Phillips screwdriver to align spacer H 37 with the mounting lugs in the lower muffler support bracket H 19 with the muffler support bracket 18 Install bolt H 35 and washer H 36 in lower lug of bracket 18 Insert screw far enough to engage the outermost screw threads in the lower support bracket 18 do not tighten screw at this time Install new exhaust flange gasket H 21 and connect exhaust flange to the muffler Tighten all fasteners
93. uity of the diode circuitry Refer to Table 9 for continuity charts for both analog and digital meters DC coil fault 4 Check the diode rectifier Check resistance between leads from stator see Table 6 If resistance reading is much larger or smaller than the specified value the DC coil of the stator is faulty Replace stator Engine speed does not increase when load applied Solenoid damaged Check bend angle of solenoid bracket Correct as required Wattage of connected appliance or electric tool exceeds rating Check rating of connected appliance or electric tool exceeds rating Use appliance or tool having compatible rating Check the slow set RPM Normal idling speeds are as follows Troubleshooting Page 32 Tsurumi s Operation Service and Repair Manual FAULT PROBABLE CAUSE REMEDY Engine speed does Wattage of connected not increase when appliance or electric tool load applied exceeds rating continued continued TPG 2900H DX 1900 to 2100 RPM TPG 4300H DX 2000 to 2200 RPM TPG 6000H DX 2000 to 2200 RPM TPG 7000H DXE 2000 to 2200 RPM NOTE The engine speeds are for a cold engine If the engine speed adjustment screw is out of its adjustment range move the solenoid backward 3 Check the wiring through the coil on the idle control unit SINGLE VOLTAGE TYPE Make sure that an output wire form the main coil is passing through the coil on th
94. upport 2 74 F080000300 Base Plate Battery 1 75 F241000050 Plate Battery Shield 1 76 F090000130 Plate Battery Hold down 1 TT F100000011 Rod Tie Down M6 X 200 2 78 F091000031 Clip 2 79 0021506000 Wing Nut Tie Down M6 2 80 0013708020 Bolt and Washer Assembly Tube to Frame M8 x 20L 4 81 0022008000 Nut Self locking M8 4 82 0013706040 Bolt and Washer Assembly Base Plate to Tube M6 X 40L 4 83 0022006000 Nut Self locking M6 4 84 0013706040 Screw and Washer Assembly Shield to Tube M6 X 40L 4 85 0022006000 Nut Self locking M6 4 86 B040000451 Cord Battery Not Shown 2 NOTE Components listed above are available in Kit BTKTPG7000 Replacement Parts Page 80 Tsurumi s Operation Service and Repair Manual APPENDIX A BATTERY ENCLOSURE KIT ASSEMBLY AND INSTALLATION INSTRUCTIONS FOR TSURUMI MODEL TPG 7000H DXE PORTABLE GENERATOR Page A 1 Appendix A Tsurumi s Operation Service and Repair Manual ASSEMBLY AND INSTALLATION INSTRUCTIONS FOR TSURUMI PORTABLE GENERATOR BATTERY ENCLOSURE 7 T 6 Ref Part No Description Qty Ref Part No Description Qty 1 F200000260 Tube Battery Support 2 10 0022006000 Nut Self Locking 4 2 F080000300 Base Plate Battery 1 11 0013706040 Bolt and Washer Assembly 4 3 F241000050 Plate Battery Shield 1 Base Plate to Tube 4 F090000130 Plate Battery Hold down 1 12 0022006000 Nut Self Lockin
95. w lt e Yellow C ET e Wiring Diagram Model TPG 7000H DXE Troubleshooting Page 38 Tsurumi s Operation Service and Repair Manual 6 REMOVAL INSTALLATION Repair of the generator is limited to the replacement of failed components This section provides the procedures for removal of failed components and installation of replacement components Exploded views and other Illustrations are provided to supplement the replacement procedures The item numbers used in the component replacement procedures are identical to item numbers in the Replacement Parts section Refer to the Replacement Parts section for part numbers of replacement parts Table 10 provides torque values for the fasteners used on the generator Tighten the fasteners to torque value shown to provide the required clamping force Table 10 Fastener Torque Values Ref No Fastener Size Model Ft lbs N m Kg cm 4 Through Bolt M8 M8 TPG 2900H DX 8 7 10 1 11 8 13 7 120 140 Through Bolt M10 M10 TPG 4300H DX 17 4 18 8 23 5 25 5 240 260 TPG 6000H DX TPG 7000H DXE 8 Rear Cover to Front Cover Screws M6 TPG 2900H DX 3 6 4 3 4 5 5 9 50 60 Rear Cover to Front Cover Screws M8 TPG 4300H DX 3 6 4 3 4 5 5 9 50 60 TPG 6000H DX TPG 7000H DXE 11 Brush Cover Screws M5 TPG 4300H DX 2 9 3 3 3 9 4 4 40 45 TPG 6000H
96. wiring and install replacement receptacle 47 in back of front panel 29 and secure with two screw and lock washer assemblies 48 For receptacle 49 remove two screw and lock washer assemblies 50 Disconnect wiring Connect wiring and install replacement receptacle 49 in back of front panel 29 and secure with two screw and lock washer assemblies 50 Install front panel 29 and control box 32 refer to Removal Installation of Front Panel and Control Box GFCI Receptacles n Refer to Figure 36 Remove front panel 29 and control box 32 refer to Removal Installation of Front Panel and Control Box Remove two screw and lock washer assemblies 45 and receptacle 42 Disconnect wiring and remove receptacle Connect wiring to replacement receptacle Install two screw and washer assemblies 45 through screw holes in front panel 29 Install receptacle 42 Secure with the two screw and washer assemblies 45 and two nuts 43 Install front panel 29 and control box 32 refer to Removal Installation of Front Panel and Control Box Page 61 Removal Installation 7 STORAGE INSTRUCTIONS WARNING Tsurumi s Operation Service and Repair Manual TO AVOID SEVERE BURNS OR FIRE HAZARDS LET THE ENGINE COOL BEFORE TRANS PORTING IT OR STORING IT INDOORS WHEN TRANSPORTING THE GENERATOR TURN THE FUEL SHUTOFF VALVE TO THE OFF POSITION AND KEEP THE ENGINE LEVEL TO PREVENT FUEL SPILLAGE FUEL V

Honda Power Equipment TPG-4300H-DX Portable Generator User Manual

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